An ASTM D178 Class 2 insulation mat is a high-performance electrical safety rubber mat rated for working environments where voltages reach up to 17,000 volts AC. It conforms to the ASTM D178 standard and is the most widely specified class for medium-to-high voltage industrial installations such as 11 kV substations and 15 kV switchgear rooms.
Class 2 mats strike the balance between sufficient protection and practical thickness, making them the most popular choice across power plants, substations, oil refineries, and large industrial complexes worldwide.
Technical Specifications of Class 2 Switchboard Mat
| ASTM Class | Class 2 |
| Max Use Voltage (AC) | 17.0 kV (17,000 V) |
| AC Proof Voltage | 20.0 kV (20,000 V) |
| Dielectric Withstand | 30.0 kV (30,000 V) |
| Recommended Thickness | 6.4 mm |
| Standard Roll Width | 1.0 m (customisable up to 1,220 mm) |
| Standard Roll Length | 10.0 m |
| Weight per Roll | Approx. 92 kg |
| Colour | Black (standard); custom colours on request |
| Anti-Skid Surface | Fine ribbed top, textured bottom |
| Material | Premium elastomer compound |
| Type | Type I (standard) | Type II (ozone, flame, oil resistant) |
| Product Code (Type I) | IM-ASTM-C2T1-BLAFT-6.4MM |
| Product Code (Type II) | IM-ASTM-C2T2-BLAFT-6.4MM |
Where is an ASTM D178 Class 2 Mat Used?
Class 2 is the most commonly specified ASTM D178 mat for medium-to-high voltage environments. Typical applications include:
- 11 kV electrical substations, the most common installation voltage globally.
- Power generation plants like generator rooms, turbine control areas.
- Large industrial switchboard rooms handling 6.6 kV to 15 kV systems.
- Transformer stations with primary voltages below 17 kV.
- Oil and gas platforms and refineries with MV electrical systems.
- Mining operations with 11 kV distribution switchgear.
- Railway traction substations.
- Data centre primary electrical rooms.
For projects specifying 11 kV protection, Class 2 is the industry standard choice.
Why is 6.4 mm Thickness Important in Class 2 Mat?
The 6.4 mm thickness of the Class 2 mat provides three key advantages:
Higher dielectric strength: The greater rubber depth creates more resistance to electrical breakdown, enabling protection up to 30,000 V.
Better mechanical durability: Thicker mats are less prone to puncture and wear, especially in high-traffic industrial regions.
Worker comfort: A 6.4 mm mat provides better anti-fatigue cushioning for workers standing for long periods in front of switchgear or control panels.
Note: Roll lengths for Class 2 and below (up to 6.4 mm) can be up to 30 m. For Class 3 mat and Class 4 mat (above 6.4 mm), the maximum roll length is 15 m.
Type I vs Type II: Class 2 Electrical Mat
Type I Class 2 mats provide standard electrical insulation and moisture resistance and are suitable for the vast majority of 11 kV substation installations. Type II Class 2 mats add:
- Ozone resistance (Type IIA): No visible effect on surface after ozone exposure.
- Flame resistance (Type IIB): Self-extinguishing after 30 seconds max char height of 12.7 mm.
- Oil and water resistance (Type IIC): Max 4% volume increase after oil immersion.
For oil refineries, chemical plants, and offshore platforms, Type II Class 2 mats are strongly recommended.
Real-World Project: Qatar Gas NFPS Phase II
AmeriVolt (Duratuf) supplied ASTM D178 Class 2 insulation mats to the Qatar Gas North Field Production Sustainability (NFPS) Phase II project; one of the world’s largest LNG expansion projects. The mats were installed in critical electrical zones prone to electrical hazards, reducing operational downtime by up to 55% and providing a reliable barrier against electrical contact in damp and demanding conditions.
Key Features & Benefits of AmeriVolt Class 2 Mats
Here are some important features of ASTM Class 2 insulation mat:
- Dielectric tested at 30,000 V; Well above the 17,000 V working rating for a strong safety margin.
- Proof tested at 20,000 V across every square metre of the roll.
- Anti-slip surface on top; anti-skid textured base prevents mat from shifting.
- Clear labelling every metre: Class, Max Use Voltage, Proof Voltage, Withstand Voltage.
- Ageing properties tested at 70°C for 168 hours and tensile strength retains at least 50% of original value.
- Moisture absorption under 1.5% (Type I) ensuring consistent insulation in humid areas.
- Certifications: ASTM, IEC, CE, RoHS, REACH, ISO 9001:2015, AIRIA, ERDA.
- Available in anti-skid design on both sides.
AmeriVolt ASTM D178 Class 2 Insulation Mats are ideal for 11 kV substations and medium-high voltage installations. Trusted by Siemens, Aramco, ABB, and hundreds of leading companies across 52 countries. Ready stock available. Contact us for test certificates and bulk pricing.
