Does a thicker electrical insulation mat necessarily offer better protection?

Not necessarily. The thickness of an electrical insulation mat does not directly indicate its electrical protection rating, nor can the safety of a product be judged solely by its thickness in millimetres. The correct choice should first meet the electrical ratings and testing requirements specified in the applicable standards, and then determine the thickness by taking into account the product’s material properties, flexibility, mechanical operating conditions and on-site installation requirements. Greater thickness does not equate to a higher insulation rating; products that comply with standards and have passed the relevant tests form the basis for a reliable selection.

Why do thicker insulating mats not necessarily offer better electrical protection?

Many procurement officers compare product thickness first when selecting electrical insulating mats. For example, if one product is 6 mm thick and another is 10 mm thick, one might intuitively assume that the 10 mm product offers better insulation.

However, this judgement is insufficient.

The protective performance of electrical insulation mats depends on the material itself, the manufacturing process, the product structure and the results of the prescribed electrical tests. Thickness is merely one parameter and cannot, on its own, prove that a product can withstand higher voltages.

Thickness is no substitute for electrical performance testing

Even if two insulating mats of different thicknesses are made from similar rubber materials, it is not possible to determine which offers better electrical protection based solely on thickness.

Actual performance is also influenced by the following factors:

• Propriétés matérielles: The rubber formulation and the electrical insulation characteristics of the material itself.
• Material uniformity: Whether there are any internal defects in the product that could affect insulation performance.
• Processus de fabrication: Whether moulding, vulcanisation and production quality are consistent.
• La structure du produit: Whether the product complies with the structural and performance requirements specified in the relevant standards.
• Résultats des tests électriques : Whether the actual product has passed the prescribed tests for the applicable rating.

For example, a standard rubber mat 10 mm thick cannot be deemed to offer higher electrical protection solely on the basis of its thickness compared to a 6 mm insulating mat that has been verified to the relevant class under IEC 61111.

If a supplier provides only thickness data without the corresponding product class and test documentation, procurement personnel cannot confirm on that basis whether the product is suitable for the intended electrical working environment.

Thickness and electrical class are two distinct concepts

The rating of an electrical insulating mat indicates the product’s electrical performance requirements under specified standard conditions, whilst thickness is a structural parameter of the product.

Although the two are related, they cannot be equated directly.

For example, IEC 61111 specifies the performance requirements and maximum thickness for insulating mats of different ratings. Products conforming to a particular rating must pass the corresponding standard tests; they do not automatically attain that rating merely by meeting the specified thickness.

Therefore, when selecting an insulating mat, one should first determine the required electrical rating, then verify the product’s thickness and test evidence; one should not simply choose the thickest product and assume it offers a higher level of protection.

What are the requirements for insulating mat thickness in IEC 61111:2026?

IEC 61111:2026 is a key technical standard for electrical insulating mats, applicable to mats made of flexible insulating material that are laid on surfaces where personnel stand and provide electrical protection.

This edition was officially published on 4 September 2026, and its scope covers AC electrical installations up to 36,000 V AC, as well as corresponding AC and DC application conditions.

One change and requirement of particular interest to procurement personnel is the relationship between the maximum thickness of insulation mats of different classes and the flexibility of the product.

Maximum thickness for different IEC classes

According to Clause 4.3.3.2 and Table 2 of IEC 61111:2026, the maximum thicknesses for insulation mats of different classes are as follows:

Please note: these figures represent the maximum thicknesses specified by the standard; they are not mandatory target thicknesses for each class.

Par exemple :

• The maximum thickness for a Class 0 insulating mat is 6 mm; this does not mean that the product must be exactly 6 mm thick.
• The maximum thickness for a Class 2 insulating mat is 8 mm; this does not mean that a product measuring 8 mm automatically meets Class 2 requirements.
• The maximum thickness for Class 4 insulating mats is 14 mm; however, this does not imply that a standard rubber mat measuring 14 mm possesses Class 4 electrical protection capabilities.

The standard does not specify a uniform minimum thickness in millimetres applicable to all products. The minimum thickness of a product depends on whether it can pass the relevant tests specified in Chapter 5 of the standard.

Therefore, when purchasing, one should verify the actual thickness, product class and corresponding test data simultaneously.

Why does the standard also specify a maximum thickness?

IEC 61111:2026 explicitly identifies appropriate flexibility as a factor in determining the maximum thickness limit.

Insulating mats must not only meet electrical performance requirements but also be capable of being laid and used in actual working areas.

If product design focuses solely on increasing thickness whilst neglecting flexibility, this may affect the rolling and unrolling, handling, laying and edge joining of the rolls.

This illustrates that the standard does not simply require insulation mats to be as thick as possible, but rather demands that products maintain physical characteristics suitable for their intended use whilst meeting the specified electrical performance requirements.

What practical problems might excessively thick electrical insulation mats cause?

Exceeding the actual thickness required does not necessarily provide additional practical value. For insulating mats that need to be frequently laid out, moved or rolled up, this may also increase the difficulty of on-site operations.

1. Reduced flexibility makes laying and handling more difficult

Electrical insulating mats are typically used in the operational areas of switchgear, distribution boards, substations and industrial electrical equipment.

If the product is too thick, and the materials and structure have not been properly designed for flexibility, the following issues may arise:

• Rolling up and unrolling the mat becomes more difficult.
• It does not fit snugly against the floor at corners and edges of equipment.
• More space is required for handling and re-laying.
• It is difficult to reposition the product within confined working areas.

These factors are particularly worth considering for portable insulating mats that need to be moved regularly.

Of course, actual flexibility also depends on the rubber material, formulation and structure; one cannot conclude simply on the basis of thickness that a particular product will be difficult to bend.

2. Increased edge height requires consideration of on-site joining

Insulating mats are typically laid in areas where personnel stand and equipment is operated.

If the product thickness increases significantly, the following should also be checked:

• The height difference between the edge of the insulating mat and the floor.
• Whether this affects the normal opening of nearby doors or equipment.
• Whether this affects personnel’s ability to walk normally within the operational area.
• Whether there is a risk of the edges curling up or causing tripping hazards.
• Whether height differences are likely to occur when multiple insulating mats are joined together.

For example, when laying insulating mats in front of switchgear, procurement staff must not only confirm the product grade and thickness but also verify the actual height after installation and the edge transitions based on the on-site floor conditions.

It is important to emphasise that thicker insulating mats do not necessarily pose a safety risk; however, if installation conditions are not taken into account, they may introduce new operational issues whilst addressing electrical protection requirements.

3. Thicker does not necessarily mean more wear-resistant or durable

This is another common procurement misconception.

Some buyers believe that the thicker the insulating mat, the less likely it is to be worn down, scratched or punctured.

In fact, mechanical durability is not solely related to thickness; it also depends on:

• the rubber material and formulation.
• the material structure and manufacturing process.
• the surface design and anti-slip performance.
• the actual risks of abrasion, tearing and puncture.
• Test results for the relevant mechanical properties of the product.

For example, consider two rubber insulating mats with different formulations: one is thicker and the other thinner. However, thickness alone cannot be used to determine which has better wear or tear resistance.

If there is a risk of frequent friction, the movement of heavy equipment or other mechanical damage at the site, products with appropriate performance characteristics should be selected based on actual usage conditions, rather than simply increasing the thickness.

How to select the appropriate insulation mat thickness for practical applications?

The correct selection process should be to first determine the electrical protection requirements, and then confirm whether the thickness and product structure are suitable for on-site use.

Step 1: Determine the required IEC electrical rating

First, determine the required insulation mat rating based on the system conditions of the electrical installation, applicable standards and on-site safety requirements.

One must not first select a product based on its thickness and then retroactively infer which voltage environments it is suitable for.

If the project specifies IEC 61111, the specific class and applicable edition must be clearly defined and included in the procurement specifications.

Step 2: Verify that the thickness complies with the requirements of the corresponding class

Once the class has been determined, check whether the product’s thickness complies with the maximum thickness requirements of the relevant standard.

Par exemple :

For products with a corrugated or diamond-patterned surface, attention must also be paid to the thickness measurement locations specified in the standard; measurements must not be taken solely at surface depressions whilst ignoring the raised areas.

Step 3: Verify the product test documentation

Purchasing personnel should request that the supplier provide technical documentation corresponding to the actual product model.

Points clés à vérifier :

• Applicable IEC 61111 class.
• Product’s rated operating conditions.
• Specified electrical test results.
• Product thickness and measurement basis.
• Identification du produit et informations sur le lot.
• Corresponding test reports or compliance documents.

The test documentation must correspond to the actual model and configuration supplied.

A test report for one product cannot be used to directly demonstrate that another product—with a different thickness, material or structure—complies with the same requirements.

Step 4: Confirm flexibility and on-site installation conditions

Electrical insulation mats must remain securely laid within the actual working area.

Therefore, the following should also be checked in conjunction with on-site conditions:

• Whether the product is easy to unroll and lay.
• Whether it is suitable for the actual floor conditions.
• Whether the surface has an appropriate anti-slip texture.
• Whether the edges obstruct pedestrian traffic.
• Whether the product dimensions meet the coverage requirements for the equipment operating area.
• Whether the roll material is convenient for subsequent storage and replacement.

If the project requires the insulation mats to be moved regularly, particular attention should be paid to flexibility and ease of handling.

Step 5: Confirm mechanical performance requirements and electrical ratings separately

If a project requires both electrical protection and involves a high risk of mechanical wear, these two types of requirements should be specified separately.

The electrical rating should be verified against applicable standards and electrical test data; mechanical durability should be assessed based on specific operating conditions and corresponding performance evidence.

Do not treat increasing thickness as a one-size-fits-all solution to all mechanical damage issues.

What key points should be verified when procuring electrical insulation mats?

For power companies, EPC project procurement staff and industrial equipment distributors, it is recommended to clarify the following during the quotation stage:

When procuring, do not simply ask the supplier:

What is the thickness of your electrical insulating mat?

A more effective approach to requesting a quotation is to provide the required IEC class, project application conditions and dimensional requirements simultaneously, allowing the supplier to provide the corresponding thickness specifications and technical documentation based on the specific model.

This helps to minimise selection errors caused by comparing thickness solely in terms of millimetres.

Conclusion: Choose the appropriate thickness rather than blindly pursuing greater thickness

The thickness of an electrical insulation mat is an important product parameter, but it does not solely determine the product’s electrical protection capability.

IEC 61111:2026 specifies maximum thickness requirements for different ratings, whilst also taking into account the appropriate flexibility the product should possess. Actual selection should be based on electrical ratings and test requirements, followed by verification of thickness, material properties, flexibility and on-site installation conditions.

For procurement personnel, the real focus should not be on which insulating mat is the thickest, but rather on which product meets the project requirements and is backed by technical evidence corresponding to the actual model.

JINPOWER offers electrical insulation mats in various IEC classes and specifications; product thickness, surface texture, dimensions and relevant technical documentation can be assessed according to project requirements.

Merci de consulter le JINPOWER electrical insulation mat product range, and provide the required IEC class, operating environment and dimensional requirements to confirm the appropriate product configuration.

Consignes de sécurité: Electrical insulation mats are auxiliary insulation protection equipment and cannot replace appropriate electrical isolation, earthing measures and safe working procedures. Specific selection and use should comply with applicable standards, on-site risk assessments and the manufacturer’s instructions.