SYLGARD®

High Voltage Insulator

Coating
A guide to proper application
A Ready-to-Use Coating
SYLGARD High Voltage Insulator Coating (HVIC)
is a one-component, ready to use silicone elastomer
dispersion designed for use on high voltage insulators
to prevent flashover and arcing, especially in severely
contaminated environments.
SYLGARD HVIC:
• Has the longest proven RTV coating field
performance
• Resists airborne contaminates
• Remains virtually maintenance-free
• Is cost effective
• Is spray applied with no mess & good finish
Use SYLGARD HVIC:
• As a protective coating - for glass and porcelain insulators,
lightning arresters, bushings and post insulators.
• Against dampness and pollution – where applying
SYLGARD HVIC overcomes flashover problems
• On polymer insulator surfaces – after priming and special
surface preparation.
Use this application guide to get consistent high-quality results
for your high voltage insulation application projects.
“Choose SYLGARD
HVIC for high reliability and low lifetime running costs –
© 1998, 2001 Dow Corning Corporation. All rights reserved.
Follow these guidelines for best results:
• Clean all surfaces of dust, grease and wax
If washing is first required, use non-soapy detergents, rinse
surfaces well and allow them to dry.
If the insulators have previously been coated with silicone
compounds or other types of greases, first clean off the old
compound. If the old grease does not come off easily by hand,
try using diesel or paraffin diluted with an emulsifiable
degreasing fluid.
Remove the final grease film with a non-polar solvent and clean
the insulator surface with isopropyl alcohol immediately prior to
application of SYLGARD HVIC.
Do not use soaps, which act as release agents and make good
adhesion impossible.
• Check temperature and humidity when applying
Because SYLGARD HVIC is a one-part room temperature
vulcanising material, moisture causes it to cure. When humidity
is relatively high, cure is faster.
Both temperature and humidity affect tack free and cure times.
When temperature and humidity are high, tack free and cure times
are shorter, while when temperature and humidity are low, tack free
and cure times are longer.
• For maximum protection, apply a total dry thickness of 0.5 mm
- SYLGARD HVIC is normally applied in two to three coats,
depending upon the method and equipment used.
- For maximum protection and life expectancy, a total dry
thickness of 0.5 mm (0.020 in) is recommended.
- Measure thickness using a wet film thickness gauge. Please note
that 0.7 mm (0.28 in) of wet film is required for 0.5 mm
(0.20 in) of cured SYLGARD HVIC.
- Cured or dry film thickness can be measured with an ultrasonic
thickness gauge.
 œ Applying SYLGARD HVIC
–
— Setting up the spray equipment
Œ
À Ã
 
Õ Spray gun
• 1 kilogram of SYLGARD HVIC covers 1.034 m2 of insulator
surface
- 1 kilogram of SYLGARD HVIC as supplied will cover 1.034 m2
of insulator surface at a cured thickness of 0.5 mm.
(1 lb covers 744 in2 at 0.20 in thickness).
- This coverage excludes losses resulting from material left in
the container and spray equipment, together with losses from
over-spray.
- For application by inexperienced sprayers, or onto insulators with
small diameters where over-spray is likely, it is recommended that
a 15% wastage factor be used in quantity calculations. (So, 1 kg
of SYLGARD HVIC will coat 0.9 m of insulator surface.)
2
• Dilute properly for easy application
- Before use, thoroughly agitate SYLGARD HVIC on a paint
shaker or a can roller to ensure uniformity.
- Thinning may be required, depending on the application
equipment to be used and the humidity and temperature
conditions.
- Some diluting may even be required for brush application.
- To dilute, use a high flash point (40˚C or above) naphtha spirit
solvent similar to solvent 360 from shell oil or white spirit.
- Add the solvent in small amounts and mix thoroughly at each
step. The final mixture must be homogeneous.
only one application gives a long-lasting maintenance free solution.”
A variety of application methods are possible, depending on your
needs. Apply by spraying, brushing or dipping. Spraying is the most
common method.
Uncoated insulator
Use dry air or
nitrogen
Air to atomise at gun
HVIC line
SYLGARD Coated insulator
SYLGARD HVIC Spray setup
Compressor Pump
• Always wear gloves when mixing. First agitate thoroughly in a pail
or separate container. Then dilute by slowly adding solvent in small
amounts. Make sure the final mixture has uniform thinness.
• Connect the airline from the compressor to the spray pump air
inlet  . Connect hose lines from the air outlet À and the
SYLGARD HVIC outlet à on the pump to the spray gun.
• Adjust compressor and pump settings Õ so that fluid comes out
of the gun nozzle when trigger — is pressed. Close the air-
adjusting valve Πsituated either in the gun handle or at the pump
air regulator module.
• Screw gun spray pattern adjustment œ all the way in, and then
back out 1/2 to 3/4 of a turn. Turn the SYLGARD HVIC volume
adjustment valve – all the way in, and then, with pressure on the
trigger —, turn slowly out again until SYLGARD HVIC spray just
emits from the nozzle.
• Open the air adjusting valve Œ to give suitable atomisation of
the SYLGARD HVIC. Use this setting for the initial coat on the
insulator.
• When spraying additional coats, you will need to adjust the valves
to get a larger volume spray pattern and for more SYLGARD HVIC.
• When spraying SYLGARD HVIC, always wear eye protection
and rubber gloves. If spraying inside, or in a locaiton with poor
ventilation, you should also use respirators along with safety
glasses.

Applying SYLGARD HVIC
with spray equipment.
Applying the first coating
• Apply first coating in a thin layer. This will ensure a build-up
without any runs or streaks. The first coat can run easily, so apply
a light ‘flash coat’ first. Allow first coat to dry for 10-15 minutes.
When first coat becomes tacky, apply subsequent coats.
Applying 2nd & 3rd coatings
• After the first coating, the next coatings should be applied whilst
the surface is tacky (wet-on-wet), and can be applied more thickly.
• Spray in a long, slow arc motion until ripples appear in the coating
surface. When this happens, move on to another part of the
insulator. Do NOT continue to spray after rippling to avoid runs.
• Spray until pail is empty, or, for continuous spraying, top up pail
with SYLGARD HVIC and solvent mixture that has been prepared
in a separate container.
Notes:
• Cured thickness should be around 0.5 mm +/- 0.14 mm and 0.7
mm uncured. Check this during spraying using a wet film gauge
• If an insulator has numerous skirts, it may not be possible to get
the full 0.5 mm thickness on the underside. In such cases, make
sure that at least one good coat is applied so that the insulator
base colour is not visible.
• Coated surfaces can be touched or will be tack-free in about
30 minutes. A full, final cure usually takes 8 hours.
Equipment clean up
• Clean spray equipment and hoses so that SYLGARD HVIC does
not cure in the gun, pump or hoses and cause blockages.
Follow the steps below:
• Fill the pump pail 1/4 full with solvent.
• Open both spray gun control valves Œœ to allow free fluid and
airflow.
• Spray the atomised solvent through the hoses and gun for a few
seconds.
• Then, close the air valve Œ on the spray gun handle, and spray the
remaining solvent un-atomised through the system.
• Blend saved solvent with SYLGARD HVIC for the next operation
• Remove pail, wipe out with a clean cloth.
• Add more clean solvent, and spray again through the system and
save for next time.
• During the second cleaning, unscrew the gun nozzle and spray the
solvent through the nozzle holes in both directions.
• Pour away any remaining solvent from the pail and wipe dry with
a clean cloth.
Spray equipment options
Various types of spraying equipment can be used:
• Air-assisted airless spray sets give the best finish with the air
atomisation of the product.
• Airless equipment can also be used to minimise over-spray losses
and gives a higher build-up per gun pass.
• For small quantity applications, it is also possible to use siphon
type spray equipment, but more coats are required to achieve the
0.5 mm thickness and the material would need significant thinning.
Using air assisted-airless spray Re-coating
equipment: procedure
• Use a Graco “Monarch” or similar • Clean the entire insulator with a solution of isopropyl alcohol
air powered 5:1 to 10:1 ratio diluted with 50% clean water.
divorced pump (or similar) with • If the adherence and thickness of the original coating is little
wetted parts manufactured from affected, the entire insulator can be “over-coated” with an
stainless steel/PTFE. additional coat of new SYLGARD HVIC if necessary. The dry film
• Mount the spray set on a two- thickness of the additional coat would be around 0.25 mm.
wheeled mobile trolley.
• Fit the fluid inlet of the pump with Coating surfaces of polymer
a flexible suction hose, complete insulators
with a rigid riser tube. • It is also possible to coat the
• The pump air motor is completed with a twin air regulator module surfaces of polymer insulators
to facilitate control of pump operating pressure and gun atomising with SYLGARD HVIC.
pressure. • Clean the surfaces of such insulators,
• Connect air atomising regulator to a brass manifold fitted with and apply DOW CORNING ® 1200
4 manual isolation valves. OS primer, or DOW CORNING
• Fit the fluid outlet of the pump with an inline filter assembly, HV1860/120 primer or low VOC
complete with fluid dump valve and a connecting hose to a brass 5200 primer before coating to ensure
manifold fitted with 4 manually operated material isolation valves. good adhesion.
• Each of the 4 material isolation valves is suitable for connecting air • See specific primer data sheets for
and fluid hose kits (say 20 metres long). Each hose kit terminates full primer application details.
with an air spray gun similar to the Graco type 800 with a 1.5 mm
diameter nozzle set-up. Service life
• This set-up allows the use of up to 4 spray guns from the same projection &
pump (could run 3 guns at height of 15/20 metres or 4 guns at assessment
ground level). • The service life of SYLGARD HVIC
• Use a portable air compressor to operate the spray pump. depends upon the severity of the
The compressor should be rated at 7 bar (100 psi) with a free contamination, insulator design and
air delivery of 1.5 cubic metres per minute (50 cfm) for 2 guns the degree of electrical stress.
and 2.25 cubic metres per minute (80 cfm) for 4 guns. In addition key elements will have been good application with the
correct application controls (cleaning and correct thickness). On
Brushing the basis of Dow Corning's experience over the last 25 years, we
• Use a soft-bristled brush to apply SYLGARD HVIC. If more than have found that many installations provide excellent service for up
one coat is required, dilute the product so that the brush will not to 10 years and beyond. However, the length of the service life will
pull the surface skin on the first coat. Clean the brush frequently. be dependent upon the factors detailed above.
Brushing does not usually give a smooth finish, but it does provide • Thin or bare spots indicate that the coating is approaching the end
the same electrical benefits as spraying. of its useful life. Loss of hydrophobicity could be another indicator.
Increases in leakage current could indicate that the coating may need
Dip coating a clean and possibly an “overcoat”.
• Good results can be obtained by dip coating for factory application.
Be sure to rotate the insulator to achieve uniform thickness and Safety requirements
prevent drips. • Because SYLGARD HVIC is combustible, do not use conventional
application methods near or on energised electrical equipment.
Touch-up procedure ensures Do not apply SYLGARD HVIC under energised conditions.
uniform coating • Use material safety data sheets (MSDS) to carefully review all
• Use a foam pad or brush to touch up or remove drips and to repair the required safety precautions for handling SYLGARD HVIC
surface flaws or damaged coating. and DOW CORNING primers.
Dow Corning Product Lines for the Electrical Power Industry
Dow Corning provides a series of cost-effective silicone insulation options for protecting electrical systems. These are designed to reduce
arcing, tracking and flashovers to improve your system reliability and lower maintenance costs. Other Dow Corning electrical products for
original equipment manufacture and maintenance include:

• Full range of silicone rubbers specially designed for high

performance composite line insulators, above and below ground
system components and substation components.
• Sealants and adhesives for site maintenance and gaskets
• Lubricants for circuit breakers and switchgear
• Dielectric compounds
• Varnishes and resins
• Insulation repair and enhancement for underground electrical cable
• Silicone transformer fluids
For more than 50 years, our high performance silicone solutions have supported the electrical industry – so rely on Dow Corning’s complete
product line that’s backed by long-term proven performance and full technical support.

Your Global Connection

Asia North America
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Tel.: +1 989 496 6000
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Tel.: +65 253 6611 South America
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Tel.: +61 1300 360 732

Europe
Dow Corning Europe
Tel.: +32 (0) 64 888 000

LIMITED WARRANTY INFORMATION - PLEASE READ CAREFULLY

The information contained herein is offered in good faith and is believed to be accurate. However, because
conditions and methods of use of our products are beyond our control, this information should not be used
in substitution for customer's tests to ensure that Dow Corning's products are safe, effective, and fully
satisfactory for the intended end use. Suggestions of use shall not be taken as inducements to infringe any
patent. Dow Corning's sole warranty is that the product will meet the Dow Corning sales specifications
in effect at the time of shipment. Your exclusive remedy for breach of such warranty is limited to refund
of purchase price or replacement of any product shown to be other than as warranted.
DOW CORNING SPECIFICALLY DISCLAIMS ANY OTHER EXPRESS OR IMPLIED
WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY. DOW
CORNING DISCLAIMS LIABILITY FOR ANY INCIDENTAL OR CONSEQUENTIAL
DAMAGES.
WE HELP YOU INVENT Dow Corning and SYLGARD are registered trademarks of Dow Corning Corporation.
THE FUTURE.™
TM
WE HELP YOU INVENT THE FUTURE is a trademark of Dow Corning Corporation.

www.dowcorning.com © 1998, 2001 Dow Corning Corporation. All rights reserved."

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