ECE-3650 SYLGARD HVIC

APPLICATION GUIDE

AUGUST 2011
ECE-3650 SYLGARD HVIC (Sylgard)
APPLICATION GUIDE FOR COATING
GLASS OR PORCELAIN INSULATORS

1) APPLICATION EQUIPMENT.
Compressor operated, 10:1 Graco pump with
Anest Iwata or equivalent spray gun. Ensure
that the air compressor is fitted with
appropriate oil and water separators so that
the air supplied to pump is dry.

2) ACCESS.
Access to the insulators would be via scaffold
or Mobile Elevated Work Platform dependant
on site layout and clearances etc.

3) INSULATOR PREPARATION.
All insulator surfaces should be completely
clean and free of dust, grease and wax and
should be dry prior to application of Sylgard.
If the insulators have previously been coated
with silicone compounds or other types of
greases, clean off the old compound first.
You will need to use solvent to remove
grease deposits. It is recommended that a
scourer saturated in solvent is used first and
then followed by a clean cloth saturated in
fresh solvent. The insulator surfaces should
then be wiped down with paper towel to
remove all residues and finally wiped with
alcohol on a clean cloth immediately prior to
spraying.

Recommended cleaning fluids:

Solvent: Shellsol D40,
Alcohol: Isoproponol IPA (with high purity)

4) APPLICATION OF SYLGARD
Sylgard can usually be sprayed undiluted, direct from its container. However, if temperature and
humidity are very high causing quicker than normal curing, it may be necessary to dilute up to a
maximum of 10% by weight of the recommended solvent (Shellsol D40). The final mixture should be
homogenous and have a viscosity suitable for spraying. The material may be mixed in the pump pail or
in a separate container. Rubber or plastic gloves should be used when mixing the Sylgard and solvent.
Do not inhale the solvent.

With the Sylgard in the pail, put the flexible suction hose into the pail. Connect the airline from the
compressor to the spray pump and the fluid & air hose kits from the pump to the spray guns. Adjust the
fluid pressure to approx. 15psi, open the fluid isolation valves and close the air isolation valves then
purge the system until Sylgard is flowing at the gun.

Open the air isolation valves and adjust the air pressure to approx. 100psi and the pump pressure to
approx. 25psi. Pressures may need to be increased if you are working at height or with very long hoses.

Vapour masks, safety glasses and rubber gloves should be worn when spraying Sylgard. If the
application is undertaken inside where there is poor ventilation an extraction unit should also be used.

The first coat of Sylgard may run easily. A light ‘flash’ coat should be applied in the first instance and
when this becomes tacky, subsequent thicker coats can be applied. Each coat needs to cure at least until
tacky before the next coat is applied. Usually a minimum of three coats (including the ‘flash’ coat) will
be required to obtain the specified thickness. Number of coats required can vary depending on the
dilution, sprayers skill and environmental conditions. The time between coats ranges from 10 minutes
to 30 minutes depending on the temperature and humidity.
Coats after the first coat may be applied heavier. Spraying action should in an arc motion until ripples
in the coating surface appear, at which time the operator should move on to another area of the insulator.
Continuing to spray after this rippling may result in runs and drips. We suggest that the tops of the
insulator shirts are sprayed first and allowed to become touch-dry followed by the underneath of the
insulator skirts. Each applicator may need to rotate between 2 or 3 insulators to allow curing time
between coats and ensure continued work. Spray until the pail is empty or, for continuous spraying, the
pail can be topped up with more Sylgard from a separate container. The spray gun nozzles/caps and
pump filters should be cleaned regularly by removing and flushing with solvent and blowing with
compressed air.

The cured thickness should be 0.5mm +/- 0.14mm approximately and this should be checked and
recorded periodically during the operation by means of an ultrasonic thickness gauge or by removing a
portion of cured Sylgard and measuring the thickness with a micrometer.

It may not always be possible to get the full 0.5mm cured thickness on parts of the insulator that are
difficult to access with the spray gun (e.g. inside of the inner profile of a multiple skirted insulator). On
these occasions it is essential that enough Sylgard be applied such that the base colour of the insulator
is not visible through the cured coating.

Providing that the correct cleaning procedure has been carried out, adhesion of Sylgard to the
porcelain/glass surface should be good. However, if it is found that the adhesion is less than adequate,
then the cleaning procedure, equipment and materials will need to be examined and the problem rectified
before any further application continues. The use of 1200 OS Primer significantly improves adhesion but
it should not be used to compensate for the lack of correct cleaning or problems associated with materials
or equipment.

Adhesion may be examined after at least 24 hours curing time by cutting a small U-shape in the cured
coating. This should then be lifted by teasing a knife blade under the front edge and peeling back. The
slice of coating should be fairly difficult to lift and should break away leaving residues of Sylgard on the
surface. The slice should NOT easily lift and tear beyond the test area. Full adhesion and curing occurs
after 7 days.

5) CLEAN-UP
Fill a bucket with solvent. Place the suction hose in the bucket of solvent and point the gun in to the
opening in the Sylgard pail. With the fluid control valve open and the air control valve closed, press the
gun trigger until all the Sylgard has been removed and solvent starts to flow from the gun nozzle, reduce
the fluid pressure and continue the cleaning operation by recycling the solvent in the bucket. Finally
flush some clean solvent through the system. Remove the filters, air caps and nozzles and clean manually.
 APPLICATION OF SYLGARD TO NON-
GLAZED INSULATORS (EG. POLYMER OR
DAMAGED PORCELAIN)

The method for coating non-glazed insulators

is similar to that for application to glass and
porcelain insulators except for the following,
which is key to the success the application.

A silicone rubber primer should be applied to

the surface of the polymer before coating with
Sylgard (step 4). The recommended primer is
Dow Corning 1200 OS. Apply a thin and even
layer of 1200 OS primer on the insulator
surfaces. This can be applied using a gravity
or siphon fed spray gun (only small amount
required). Please note that 1200 OS Primer
needs to be allowed to semi-cure but not
completely cure before it is over coated with
Sylgard. Therefore, it is advisable to apply
Sylgard at least 15 minutes after but no longer
than 90 minutes after applying the primer.

Please note that it may not be advisable to use

solvent for cleaning polymer insulators.

OVER-COATING OF SYLGARD

The method for over-coating insulators is the

same as that for application to glass and
porcelain insulators except for the following,
which is key to the success of the application.

3) INSULATOR PREPARATION.
All surfaces of the existing coating should be
thoroughly cleaned with cloths soaked in a
solution of 50% IPA and 50% water to remove
surface contaminants. Do NOT use solvent for
cleaning.

The cured thickness of the overcoat should be 0.30mm +/- 0.05mm, unless there has been a serious
loss of hydrophobicity of the existing coating, and then a full 0.5mm overcoat should be applied. This
should be checked periodically during the operation by means of an ultrasonic thickness gauge or by
removing a portion of cured Sylgard and measuring the thickness with a micrometer. Please note - you
may need to take an initial thickness measurement and then measure total thickness after recoating to
get an accurate gauge of the newly applied Sylgard.

In areas where the existing Sylgard coating may have been totally removed, the area should be patch
repaired and then the cured thickness of the repair should be brought up to the thickness of the
surrounding existing coating prior to overcoating.
ABOUT CCS

Commercial Coating Systems Ltd (CCS) was founded in 1997

by Chris Cork and Barry Field. Their aim was to provide cost
effective, reliable and low-maintenance solutions for
pollution management on high voltage systems.

CCS achieved this by providing specialised products, services

and equipment for application of high voltage insulator
coatings.

Continuing to build upon the company's experience in HVIC

distribution and application, CCS developed a range of
complimentary products which has enabled us to provide a
complete service for the protection and maintenance of high
voltage systems. A new company was formed in 2009, CCS
Network Ltd, to take care of the distribution of products and
CCS is now dedicated to UK contracting.

Please see our website for products and further details.

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 the products are
beyond our control, this information should not be used in substitution for customers' tests to ensure that the 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.

CCS SPECIFICALLY DISCLAIMS ANY EXPRESS OR IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY. CCS DISCLAIMS LIABILITY
FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES.

CCS Network Ltd

Pike Road Industrial Estate
Tilmanstone
Kent CT15 4NL
UK

Tel: +44 (0)1227 830 673

Fax: +44 (0)845 867 7661
Email: info@ccs-network.com

www.ccs-network.com