Polymer Insulators up to 400kV
Composite Silicone Insulators
Suspension, tension, line post, disc, pin and post type composite insulators — lightweight, hydrophobic and maintenance-free. IEC 61109 and IS C29-11 compliant.
Overview
VIKCHEM manufactures and exports high-quality composite polymer insulators for power transmission and distribution systems rated up to 400kV. These insulators are designed for utility projects and major infrastructure installations including overhead transmission lines, substations and renewable energy facilities.
Our polymer insulators feature a silicone rubber housing providing hydrophobic properties — water beads off the surface even after long service, maintaining electrical performance in heavily polluted and coastal environments where traditional porcelain insulators regularly fail.
Insulator Types
Suspension Insulators
Used in transmission lines for supporting and suspending conductors. Available in B&S and T&C end fittings for compatibility with various line hardware.
Tension / Strain Insulators
Designed to withstand mechanical tension loads at angle towers, dead-end structures and strain sections of transmission lines.
Line Post Insulators
Used on distribution lines for supporting conductors in a horizontal or angled position. Suitable for 11kV to 33kV distribution networks.
Disc Insulators
Individual disc units that can be assembled in strings to achieve required voltage ratings. Compatible with standard hardware fittings.
Pin Insulators
Used on low and medium voltage distribution lines for direct line support. Easy installation on cross-arms and poles.
Post Insulators
Used in substations and switchgear installations for bus bars and equipment support. High mechanical strength for indoor and outdoor use.
Material Composition
| Component | Material |
|---|---|
| Insulation Housing | Silicone rubber (hydrophobic) |
| Core Rod | ECR glass fibre (corrosion-resistant) |
| End Fittings | SG iron or forged steel |
| Shed Profile | Alternating profile for rain shed |
End Fittings Available
VIKCHEM polymer insulators are available with multiple end fitting configurations to match the hardware used in different transmission and distribution line designs. The correct fitting type must be specified at time of order as it determines compatibility with the cross-arm, strain clamp and linking hardware on site.
Ball & Socket (B&S)
Standard end fitting for suspension and tension insulators on most Indian transmission lines. The ball end connects to the socket of the adjacent hardware or insulator cap. Compatible with standard IEC 60305 hardware.
Tongue & Clevis (T&C)
Alternative end fitting for tension and dead-end applications where a clevis connection is preferred. Common on older distribution lines and on some export markets. The tongue fits into the clevis pin hole of the connecting hardware.
Dead End / Eye Clamp
Used at the last tower or pole in a section where the conductor terminates. The dead-end fitting anchors the conductor and transfers the full mechanical tension load to the tower structure through the insulator string.
Arcing Horn
Optional protective fitting that diverts lightning and switching surge arcing away from the insulator surface, preventing damage to the silicone rubber sheds during overvoltage events.
Advantages Over Porcelain Insulators
Lightweight
90% lighter than equivalent porcelain insulators — reduces installation time and tower loading.
Superior Pollution Performance
Hydrophobic silicone rubber surface exhibits excellent self-cleaning properties in heavily polluted areas.
Vandalism Resistant
Do not shatter like porcelain — controlled failure mode prevents explosive breakage.
Enhanced Safety
Safe to handle — no sharp edges, no glass shards, reduced risk of injury during installation.
Reduced Maintenance
Longer service life with minimal cleaning requirements versus porcelain insulators.
Excellent Creepage
High creepage distance provides superior insulation performance in coastal and industrial zones.
Specifications
Best Suited For
- › Coastal & salt-air environments
- › Heavy industrial pollution zones
- › High humidity regions
- › Transmission lines 66kV–400kV
- › Distribution lines 11kV–33kV
- › Railway electrification
- › Wind farm & solar installations