IEC 60855-1:2016

Live working - Insulating foam-filled tubes and solid rods - Part 1: Tubes and rods of a circular cross-section

IEC 60855-1:2016 is applicable to insulating foam-filled tubes and solid rods, of a circular cross-section, made of synthetic materials with reinforced fibreglass and intended to be used in the manufacture and construction of tools, devices and equipment for carrying out live working on electrical systems operating at voltages above 1 kV. This second edition cancels and replaces the first edition published in 2009. This edition constitutes a technical revision.

Travaux sous tension - Tubes isolants remplis de mousse et tiges isolantes pleines - Partie 1: Tubes et tiges de section circulaire

L'IEC 60855-1:2016 est applicable aux tubes isolants remplis de mousse et aux tiges isolantes pleines, de section circulaire, fabriqués en matériaux synthétiques avec fibre de verre renforcée et destinés à être utilisés dans la fabrication et la construction des outils, dispositifs et équipements pour réaliser des travaux sous tension sur des réseaux électriques de tension supérieure à 1 kV. Cette deuxième édition annule et remplace la première édition parue en 2009. Cette édition constitue une révision technique.

General Information

• Status: Published
• Publication Date: 26-Apr-2016
• ICS: 13.260 - Protection against electric shock. Live working
• ICS: 29.240.20 - Power transmission and distribution lines
• ICS: 29.260.01 - Electrical equipment for working in special conditions in general
• Technical Committee: TC 78 - Live working
• Drafting Committee: WG 12 - TC 78/WG 12
• Current Stage: PPUB - Publication issued
• Start Date: 27-Apr-2016
• Completion Date: 15-Jun-2016

Relations

• Revises: IEC 60855-1:2009 - Live working - Insulating foam-filled tubes and solid rods - Part 1: Tubes and rods of a circular cross-section
• Effective Date: 05-Sep-2023

Overview

IEC 60855-1:2016 is an international standard published by the International Electrotechnical Commission (IEC) that specifies requirements for insulating foam-filled tubes and solid rods of circular cross-section. These components are constructed from synthetic materials reinforced with fibreglass and intended primarily for use in live working tools and equipment operating on electrical systems above 1 kV. This edition, the second release, revises the original 2009 standard, introducing technical improvements for enhanced performance and safety.

The standard focuses on ensuring the mechanical, electrical, and dimensional integrity of these insulating tubes and rods to protect workers during live electrical operations. It includes comprehensive testing protocols, conformity assessment procedures, and guidelines for manufacturing tolerances, marking, and packaging.

Key Topics

• Materials and Design: The standard requires synthetic foam-filled tubes and solid rods reinforced with fibreglass for optimal insulation, mechanical strength, and durability in live working scenarios.
• Electrical Requirements: Specifies dielectric tests before and after exposure to humidity to assess the insulation capacity, including wet tests under controlled conditions to simulate field usage.
• Mechanical Requirements: Defines tests such as bending, torsion, and crushing to verify the mechanical robustness of the insulating tubes and rods during live working.
• Dimensional Specifications: Provides exact diameters and tolerances for foam-filled tubes and solid rods, ensuring consistency in manufacturing and compatibility with tools.
• Marking and Packaging: Guidelines for clear marking to indicate compliance and safe usage, alongside packaging requirements that protect the products during shipment and storage.
• Testing and Conformity Assessment: Incorporates a set of type tests, visual and dimensional inspections, electrical and mechanical examination, and final conformity assessment to guarantee product reliability.
• Environmental Considerations: Highlights the environmental impact considerations during product lifecycle stages, encouraging manufacturers and users to adopt sustainable practices.

Applications

IEC 60855-1:2016 is critical for manufacturers and users involved in the design, production, testing, and utilization of insulating foam-filled tubes and solid rods used in live working-a safety practice essential to electrical maintenance and repair tasks on energized systems operating over 1 kV. The standard supports:

• Live Working Tools: Enabling safe development of insulating rods and tubes in tools designed for contacts with live electrical conductors.
• Electrical Maintenance Equipment: Ensuring that devices used during live line operations meet stringent insulation and mechanical strength criteria.
• Safety Compliance: Assisting manufacturers in meeting international safety requirements, reducing risk for electrical workers worldwide.
• Quality Assurance: Providing a framework for product testing and certification to deliver consistent, reliable insulating components.
• Industrial and Utility Sectors: Widely adopted in utilities, power generation, and industrial plants where live working methods improve operational efficiency and safety.

Related Standards

• IEC 61477: Pertains to live working equipment, detailing safety requirements; IEC 60855-1 complies with its framework for insulating materials.
• Other IEC 60855 Series Parts: Including potential future parts addressing foam-filled tubes and rods with non-circular cross-sections.
• IEC Testing Standards: Complementary electrical and mechanical testing protocols applicable for live working apparatus.
• ISO/IEC Directives, Part 2: Governing the drafting and format of international standards, ensuring IEC 60855-1 adheres to global documentation norms.

---

Keywords: IEC 60855-1, insulating foam-filled tubes, solid rods, live working, electrical safety, dielectric tests, fibreglass reinforcement, live working tools, insulating rods, mechanical tests, electrical insulation, high voltage equipment, safety standards, electrical maintenance, IEC standards, live line working equipment.

Standards Content (Sample)

IEC 60855-1 ®
Edition 2.0 2016-04
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Live working – Insulating foam-filled tubes and solid rods –
Part 1: Tubes and rods of a circular cross-section

Travaux sous tension – Tubes isolants remplis de mousse et tiges isolantes
pleines –
Partie 1: Tubes et tiges de section circulaire

All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized in any form
or by any means, electronic or mechanical, including photocopying and microfilm, without permission in writing from
either IEC or IEC's member National Committee in the country of the requester. If you have any questions about IEC
copyright or have an enquiry about obtaining additional rights to this publication, please contact the address below or
your local IEC member National Committee for further information.

Droits de reproduction réservés. Sauf indication contraire, aucune partie de cette publication ne peut être reproduite
ni utilisée sous quelque forme que ce soit et par aucun procédé, électronique ou mécanique, y compris la photocopie
et les microfilms, sans l'accord écrit de l'IEC ou du Comité national de l'IEC du pays du demandeur. Si vous avez des
questions sur le copyright de l'IEC ou si vous désirez obtenir des droits supplémentaires sur cette publication, utilisez
les coordonnées ci-après ou contactez le Comité national de l'IEC de votre pays de résidence.

IEC Central Office Tel.: [phone]
3, rue de Varembé Fax: [phone]
CH-1211 Geneva 20 [e-mail]
Switzerland www.iec.ch
About the IEC
The International Electrotechnical Commission (IEC) is the leading global organization that prepares and publishes
International Standards for all electrical, electronic and related technologies.

About IEC publications
The technical content of IEC publications is kept under constant review by the IEC. Please make sure that you have the
latest edition, a corrigenda or an amendment might have been published.

IEC Catalogue - webstore.iec.ch/catalogue Electropedia - www.electropedia.org
The stand-alone application for consulting the entire The world's leading online dictionary of electronic and
bibliographical information on IEC International Standards, electrical terms containing 20 000 terms and definitions in
Technical Specifications, Technical Reports and other English and French, with equivalent terms in 15 additional
documents. Available for PC, Mac OS, Android Tablets and languages. Also known as the International Electrotechnical
iPad. Vocabulary (IEV) online.

IEC publications search - www.iec.ch/searchpub IEC Glossary - std.iec.ch/glossary
The advanced search enables to find IEC publications by a 65 000 electrotechnical terminology entries in English and
variety of criteria (reference number, text, technical French extracted from the Terms and Definitions clause of
committee,…). It also gives information on projects, replaced IEC publications issued since 2002. Some entries have been
and withdrawn publications. collected from earlier publications of IEC TC 37, 77, 86 and

CISPR.
IEC Just Published - webstore.iec.ch/justpublished

Stay up to date on all new IEC publications. Just Published IEC Customer Service Centre - webstore.iec.ch/csc
details all new publications released. Available online and If you wish to give us your feedback on this publication or
also once a month by email. need further assistance, please contact the Customer Service
Centre: [e-mail].
A propos de l'IEC
La Commission Electrotechnique Internationale (IEC) est la première organisation mondiale qui élabore et publie des
Normes internationales pour tout ce qui a trait à l'électricité, à l'électronique et aux technologies apparentées.

A propos des publications IEC
Le contenu technique des publications IEC est constamment revu. Veuillez vous assurer que vous possédez l’édition la
plus récente, un corrigendum ou amendement peut avoir été publié.

Catalogue IEC - webstore.iec.ch/catalogue Electropedia - www.electropedia.org
Application autonome pour consulter tous les renseignements
Le premier dictionnaire en ligne de termes électroniques et
bibliographiques sur les Normes internationales,
électriques. Il contient 20 000 termes et définitions en anglais
Spécifications techniques, Rapports techniques et autres
et en français, ainsi que les termes équivalents dans 15
documents de l'IEC. Disponible pour PC, Mac OS, tablettes
langues additionnelles. Egalement appelé Vocabulaire
Android et iPad.
Electrotechnique International (IEV) en ligne.

Recherche de publications IEC - www.iec.ch/searchpub
Glossaire IEC - std.iec.ch/glossary
La recherche avancée permet de trouver des publications IEC 65 000 entrées terminologiques électrotechniques, en anglais
en utilisant différents critères (numéro de référence, texte, et en français, extraites des articles Termes et Définitions des
comité d’études,…). Elle donne aussi des informations sur les publications IEC parues depuis 2002. Plus certaines entrées
projets et les publications remplacées ou retirées. antérieures extraites des publications des CE 37, 77, 86 et

CISPR de l'IEC.
IEC Just Published - webstore.iec.ch/justpublished

Service Clients - webstore.iec.ch/csc
Restez informé sur les nouvelles publications IEC. Just
Published détaille les nouvelles publications parues. Si vous désirez nous donner des commentaires sur cette
Disponible en ligne et aussi une fois par mois par email. publication ou si vous avez des questions contactez-nous:
[e-mail].
IEC 60855-1 ®
Edition 2.0 2016-04
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Live working – Insulating foam-filled tubes and solid rods –

Part 1: Tubes and rods of a circular cross-section

Travaux sous tension – Tubes isolants remplis de mousse et tiges isolantes

pleines –
Partie 1: Tubes et tiges de section circulaire

INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 13.260; 29.240.20; 29.260 ISBN 978-2-8322-3348-1

– 2 – IEC 60855-1:2016  IEC 2016
CONTENTS
FOREWORD . 4
INTRODUCTION . 6
1 Scope . 7
2 Normative references. 7
3 Terms and definitions . 7
4 Requirements . 8
4.1 Materials and design . 8
4.2 Electrical requirements . 8
4.3 Mechanical requirements . 8
4.4 Diameters of foam-filled tubes and solid rods . 8
4.5 Marking . 9
4.6 Packaging . 9
5 Tests . 9
5.1 General . 9
5.2 Type test conditions . 9
5.2.1 General . 9
5.2.2 Groups and test pieces . 10
5.3 Visual and dimensional checks . 10
5.3.1 General . 10
5.3.2 Visual check . 10
5.3.3 Dimensional check . 11
5.4 Electrical tests . 11
5.4.1 General . 11
5.4.2 Dielectric test before and after exposure to humidity . 11
5.4.3 Wet test . 20
5.5 Mechanical tests . 22
5.5.1 Bending test . 22
5.5.2 Torsion test . 24
5.5.3 Crushing test on insulating foam-filled tube . 26
5.5.4 Electrical test after mechanical ageing . 27
5.5.5 Dye penetration test . 28
5.5.6 Durability of marking . 28
6 Conformity assessment of foam-filled tubes and solid rods having completed the
production phase . 28
7 Modifications . 29
Annex A (normative) Plan of carrying out of the type tests . 30
Annex B (normative) Classification of defects and associated requirements and tests . 31
Bibliography . 32

Figure 1 – Typical dielectric test arrangement . 12
Figure 2 – Assembly set-up of the test piece to the guard electrodes . 13
Figure 3 – Constructional drawings for guard electrodes and parts . 15
Figure 4 – Drawings for guard electrode parts according to test piece diameters . 17
Figure 5 – Alternative dielectric test under dry condition – Example of a typical test
arrangement . 19

Figure 6 – Wet test . 21
Figure 7 – Bending test . 23
Figure 8 – Torsion test – Examples for fixing foam-filled tube and solid rod . 25
Figure 9 – Crushing test . 27

Table 1 – Specified diameters . 8
Table 2 – Maximum current I before exposure to humidity . 18
Table 3 – Values of F , f and F for bending test . 24
d r
Table 4 – Values of C , a and C for torsion test . 26
d d r
Table 5 – Values of F and F for crushing test . 26
d r
Table A.1 – Chronological order of the type tests . 30
Table B.1 – Classification of defects and associated requirements and tests . 31

– 4 – IEC 60855-1:2016  IEC 2016
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
LIVE WORKING – INSULATING FOAM-FILLED TUBES AND SOLID RODS –

Part 1: Tubes and rods of a circular cross-section

FOREWORD
1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising
all national electrotechnical committees (IEC National Committees). The object of IEC is to promote
international co-operation on all questions concerning standardization in the electrical and electronic fields. To
this end and in addition to other activities, IEC publishes International Standards, Technical Specifications,
Technical Reports, Publicly Available Specifications (PAS) and Guides (hereafter referred to as “IEC
Publication(s)”). Their preparation is entrusted to technical committees; any IEC National Committee interested
in the subject dealt with may participate in this preparatory work. International, governmental and non-
governmental organizations liaising with the IEC also participate in this preparation. IEC collaborates closely
with the International Organization for Standardization (ISO) in accordance with conditions determined by
agreement between the two organizations.
2) The formal decisions or agreements of IEC on technical matters express, as nearly as possible, an international
consensus of opinion on the relevant subjects since each technical committee has representation from all
interested IEC National Committees.
3) IEC Publications have the form of recommendations for international use and are accepted by IEC National
Committees in that sense. While all reasonable efforts are made to ensure that the technical content of IEC
Publications is accurate, IEC cannot be held responsible for the way in which they are used or for any
misinterpretation by any end user.
4) In order to promote international uniformity, IEC National Committees undertake to apply IEC Publications
transparently to the maximum extent possible in their national and regional publications. Any divergence
between any IEC Publication and the corresponding national or regional publication shall be clearly indicated in
the latter.
5) IEC itself does not provide any attestation of conformity. Independent certification bodies provide conformity
assessment services and, in some areas, access to IEC marks of conformity. IEC is not responsible for any
services carried out by independent certification bodies.
6) All users should ensure that they have the latest edition of this publication.
7) No liability shall attach to IEC or its directors, employees, servants or agents including individual experts and
members of its technical committees and IEC National Committees for any personal injury, property damage or
other damage of any nature whatsoever, whether direct or indirect, or for costs (including legal fees) and
expenses arising out of the publication, use of, or reliance upon, this IEC Publication or any other IEC
Publications.
8) Attention is drawn to the Normative references cited in this publication. Use of the referenced publications is
indispensable for the correct application of this publication.
9) Attention is drawn to the possibility that some of the elements of this IEC Publication may be the subject of
patent rights. IEC shall not be held responsible for identifying any or all such patent rights.
International Standard IEC 60855-1 has been prepared by technical committee 78: Live
working.
This second edition cancels and replaces the first edition published in 2009. This edition
constitutes a technical revision.
This edition includes the following significant technical changes with respect to the previous
edition:
• reintroduction of specific diameters of foam-filled tubes and solid rods of circular cross-
section with its tolerances;
• reintroduction of the dielectric tests before and after exposure to humidity, as included in
IEC 60855-1:2009;
• specification of an alternative test (after exposure to immersion) in case of foam-filled
tubes and solid rods having completed the production phase;
• review of phase angle maximum specified values;

• review of the wet test procedure and the improvement of the associated test arrangement.
The text of this standard is based on the following documents:
FDIS Report on voting
78/1147/FDIS 78/1156/RVD
Full information on the voting for the approval of this standard can be found in the report on
voting indicated in the above table.
This publication has been drafted in accordance with the ISO/IEC Directives, Part 2.
A list of all parts in the IEC 60855 series, published under the general title Live working –
Insulating foam-filled tubes and solid rods, can be found on the IEC website.
Terms defined in Clause 3 are given in italic print throughout this standard.
The committee has decided that the contents of this publication will remain unchanged until
the stability date indicated on the IEC website under "http://webstore.iec.ch" in the data
related to the specific publication. At this date, the publication will be
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.
– 6 – IEC 60855-1:2016  IEC 2016
INTRODUCTION
This part of IEC 60855 has been prepared in accordance with the requirements of IEC 61477.
The product covered by this part of IEC 60855 may have an impact on the environment during
some or all stages of its life cycle. These impacts can range from slight to significant, be
short-term or long-term, and occur at the global, regional or local level.
This part of IEC 60855 does not include requirements and test provisions for the
manufacturers of the product, or recommendations to the users of the product for
environmental improvement. However, all parties intervening in its design, manufacture,
packaging, distribution, use, maintenance, repair, reuse, recovery and disposal are invited to
take account of environmental considerations.
Technical committee 78 is considering the preparation of IEC 60855-2, which would cover
foam-filled tubes and solid rods of cross-section other than circular.

LIVE WORKING – INSULATING FOAM-FILLED TUBES AND SOLID RODS –

Part 1: Tubes and rods of a circular cross-section

1 Scope
This part of IEC 60855 is applicable to insulating foam-filled tubes and solid rods, of a circular
cross-section, made of synthetic materials with reinforced fibreglass and intended to be used in
the manufacture and construction of tools, devices and equipment for carrying out live
working on electrical systems operating at voltages above 1 kV.
Foam-filled tubes and solid rods of cross-section other than circular and/or made with material
other than synthetic materials with reinforced fibreglass are not covered by this part of
IEC 60855.
2 Normative references
The following documents, in whole or in part, are normatively referenced in this document and
are indispensable for its application. For dated references, only the edition cited applies. For
undated references, the latest edition of the referenced document (including any
amendments) applies.
IEC 60060-1, High-voltage test techniques – Part 1: General definitions and test requirements
IEC 60060-2, High-voltage test techniques – Part 2: Measuring systems
IEC 60212:2010, Standard conditions for use prior to and during the testing of solid electrical
insulating materials
IEC 61318, Live working – Conformity assessment applicable to tools, devices and equipment
3 Terms and definitions
For the purposes of this document, the terms and definitions given in IEC 61318 and the
following apply.
3.1
foam
insulating material composed of closed cells, generally made of polyurethane, used to prevent
the ingress and migration of moisture
Note 1 to entry: Foam is the inner support to manufacture the foam-filled tubes covered by this part of IEC 60855.
[SOURCE: IEC 60050-651:2014, 651-22-03, modified – The note has been changed to refer
specifically to the foam filled tubes covered by this part of IEC 60855.]
3.2
insulating foam-filled tube
foam-filled tube
tube of uniform circular cross-section supplied in straight lengths, manufactured on a foam
and constructed or formed of synthetic insulating rigid material with reinforced fibreglass

– 8 – IEC 60855-1:2016  IEC 2016
3.3
insulating solid rod
solid rod
solid product of uniform circular cross-section supplied in straight lengths, constructed or
formed of synthetic insulating rigid reinforced material
[SOURCE: IEC 60050-651:2014, 651-22-04, modified – The term and its definition have been
changed to refer specifically to insulating solid rods covered by this part of IEC 60855.]
4 Requirements
4.1 Materials and design
Foam-filled tubes and solid rods shall be made of synthetic insulating material with reinforced
fibreglass.
NOTE Yellow, orange and red are the preferred colours to indicate that the material has insulating properties.
If any coating is applied, it may be transparent or coloured.
The foam filling shall be bonded to the wall of the insulating tube, and neither the foam nor
the bond shall be deteriorated during the tests, other than those tests which lead to
destruction of the parts. The foam filling shall be free of voids, separations, cracks or other
defects.
4.2 Electrical requirements
The material and the design of foam-filled tubes and solid rods shall have insulating
properties.
The external surface of the foam-filled tubes and solid rods shall have hydrophobic properties.
4.3 Mechanical requirements
The material and the design of foam-filled tubes and solid rods shall have mechanical
resistance properties.
4.4 Diameters of foam-filled tubes and solid rods
All measured diameters shall fall within the tolerance limits specified in Table 1.
Table 1 – Specified diameters
External nominal diameter Tolerance on external diameter
Item
mm mm
10 ± 1
Solid rod
± 1
32 ± 1
39 ± 1,1
Foam-filled tube 51
± 1,2
64 ± 1,3
77 ± 1,5
4.5 Marking
Embossed marking is prohibited.
The marking of each foam-filled tube and solid rod shall include the following information as a
minimum:
• name or trademark of the manufacturer;
• external nominal diameter;
• date of manufacture (month and year) and identification number when available;
• number of the relevant IEC standard (IEC 60855-1).
Other characteristics or information not needed at the work location, like the year of
publication of the standard, shall be associated to the product item by other means, such as
coded information (bar codes, microchips, etc.) on the product or on its packaging.
The marking shall be clearly legible to a person with normal or corrected vision, without
additional magnification. The marking shall be durable and shall not affect the electrical
performance of foam-filled tubes and solid rods.
4.6 Packaging
The marking of each pack shall include the following information as a minimum:
• name or trademark of the manufacturer;
• external nominal diameter;
• date of manufacture (month and year) and identification number when available;
• number of the relevant IEC standard (IEC 60855-1).
The packaging should reduce abrasive or direct contact with other foam-filled tubes or solid
rods or any surface that could damage the polished surface.
5 Tests
5.1 General
This part of IEC 60855 provides testing provisions to demonstrate that the foam-filled tubes
and solid rods comply with the requirements of Clause 4. These testing provisions are
primarily intended to be used for type testing for validation of the design input. Where
relevant, alternative means (calculation, examination, tests, etc.), are specified within the test
subclauses for the purpose of foam-filled tubes and solid rods having completed the
production phase (see Annex B).
5.2 Type test conditions
5.2.1 General
To comply with this part of IEC 60855, the design of the product shall fulfil all the type tests
listed in Table A.1.
The type tests shall be carried out following the order given in Table A.1.
Each test shall be carried out on each separate test piece in the relevant group.
Any test piece failing to pass any one of the tests mentioned in Annex A shall result in the
design being rejected.
– 10 – IEC 60855-1:2016  IEC 2016
For all type tests, environmental conditions in the test room shall comply with the normal
atmospheric conditions provided in Table 2 of IEC 60212:2010, at a temperature of between
15 °C and 35 °C, with a relative humidity between 25 % and 75 % (taking into account Note 4
of Table 2 of IEC 60212:2010).
Nevertheless, for the electrical test the atmospheric conditions shall be at temperature
between 18 °C and 28 °C, with a relative humidity between 45 % and 75 %.
This part of IEC 60855 covers foam-filled tubes and solid rods for use at temperatures
between –25 °C and +55 °C and at a relative humidity between 20 % and 93 %. For foam-
filled tubes and solid rods intended to be used in unusual atmospheric conditions (higher or
lower temperatures, higher relative humidity), the tests should be more restricting and be
carried out in appropriate conditions.
Unless otherwise specified, for all type tests, the tolerance on the dimensions shall be
± 0,5 %.
When a visual check is specified, it shall be understood to be a visual check by a person with
normal or corrected vision without additional magnification.
5.2.2 Groups and test pieces
The manufacturer shall supply lengths of foam-filled tubes and solid rods to provide the
following groups of test pieces. For each test piece of every group the corresponding length
shall be cut at least to 0,1 m from the end of the initial length of solid rod or foam-filled tube
provided by the manufacturer.
Group 1: three test pieces of 0,3 m.
Group 2: three test pieces of 1,2 m.
Group 3: three test pieces of 2,5 m in case of foam-filled tube and 2 m in case of solid rod.
Group 4: three test pieces of 1,2 m.
Group 5: (for foam-filled tubes only): three test pieces of length equal to three times the
external diameter ± 5 %.
Group 6: three test pieces of 2,5 m.
Group 7: three test pieces of (100 ± 5) mm.
One length of 2 m shall be kept as a reference specimen.
The equipment used to cut the test pieces shall not leave any trace of overheating on the
cross-section. The cut shall be clean, showing no signs of tearing of the fibres and shall be
made perpendicular to the axis of the foam-filled tube and solid rod.
5.3 Visual and dimensional checks
5.3.1 General
These checks shall be carried out to ensure that the general requirements are fulfilled and
that the dimensions comply with the specifications.
5.3.2 Visual check
Initial lengths and test pieces shall be checked visually to verify the elements of marking, the
packaging and to detect constructional defects.
There are two levels of inspection to detect constructional defects:

a) A first visual check shall be carried out on each of the initial lengths of foam-filled tube
and solid rod provided by the manufacturer before the test pieces are cut from them. This
is to detect any surface defects such as obviously faulty bonding between the fibre and
the resin, voids underneath the varnish, foreign bodies, protrusions, dirt, bumps or
scratches and absence of marks. Any defect shall result in rejection of the initial length.
b) A second visual check shall be carried out on each of the test pieces after they have been
cut. This is to detect any internal defects around the visible part of the cross-section, and
more particularly, any signs of detachment between the foam and the resin, and foam of
poor quality (voids, cracks). Any such defect shall result in rejection of the test piece.
5.3.3 Dimensional check
The purpose of the dimensional check is to verify that diameters comply with the marking, and
the tolerances comply with the requirements of 4.4.
The dimensional check shall be carried out on each of the initial lengths, before the test
pieces are cut from them, at both ends and in the middle. The difference between any two
measured diameters of a given length shall be less than 0,5 mm.
5.4 Electrical tests
5.4.1 General
Unless otherwise stated, tests shall be carried out using an AC power source at power
frequency in accordance with the requirements given in IEC 60060-1. Measuring systems
shall comply with IEC 60060-2 unless otherwise specified.
5.4.2 Dielectric test before and after exposure to humidity
5.4.2.1 Type test
5.4.2.1.1 General test conditions
Before the test, each test piece of 300 mm length shall be prepared by cleaning with
isopropanol (CH -CH(OH)-CH ) and then dried in air at room temperature for a period of not
3 3
less than 15 min.
NOTE It is not the purpose of this part of IEC 60855 to ensure that any relevant legislation and any specific safety
instructions regarding the use of isopropanol are fully observed.
The test pieces shall be lightly wiped with a clean dry lint-free cloth and the ends of the test
pieces shall be covered with conductive adhesive tape.
Conditioning in a humid atmosphere is carried out in accordance with IEC 60212.
5.4.2.1.2 Measurements
The test assembly shall comply with Figures 1, 2, 3 and 4. The measuring apparatus shall not
be less than 2 m from the high voltage source. All measuring leads, the shunt and the optional
protective gap shall be shielded and earthed. The test piece shall be mounted at a minimum
height of 1 m from the ground on an insulating support. A voltage of 100 kV rms at power
frequency shall be applied between the electrodes for 1 min. The AC voltage shall be initially
applied at a low value and gradually increased at a constant rate-of-rise of approximately
5 kV/s until the test voltage level is reached. The test period shall be considered to start at
the instant the specified voltage is reached.
The current passing through the test piece shall be measured (the guard electrode on the
earth side is directly connected to earth). The maximum current recorded during the test is
called I.
– 12 – IEC 60855-1:2016  IEC 2016
The phase difference between current and voltage shall be measured as follows:
• current (earth end), by passing it through a known impedance;
• voltage (line end), by means of an appropriate divider.
The minimum phase angle recorded during the test is called ϕ.
Before installing the test piece in the test set-up, reference measurements with no test piece
present shall be taken and the current and phase angle values recorded. The phase angle
value shall be higher than 88°. This blank test will help verify the quality of the test set-up.
B
A
R
P
IEC
Key
1 continuous welded tube 4 screened leads
2 guard electrodes 5 measuring equipment
3 test piece 6 capacitive (or resistive) divider
A and B See Figure 2.
R resistance between points A and P: R ≤ 10 000 Ω
The measurement zone is situated at least 2 m away from any high voltage source.
Figure 1 – Typical dielectric test arrangement

B
A
IEC
Key
A insulating material B brass
1 socket for ∅ 4 mm banana plug 5 insulating support
2 guard electrode 6 contact maintained by conductive adhesive tape
3 test piece of 300 mm length 7 socket for ∅ 4 mm banana plug soldered on guard electrode
4 brass electrode
Banana plugs may be replaced by other suitable electrical connectors.
Figure 2 – Assembly set-up of the test piece to the guard electrodes

– 14 – IEC 60855-1:2016  IEC 2016
Dimensions in millimetres
ø12
ø45
ø500
IEC
Key
1 copper tube soldered onto brass plate
2 brass plate
Figure 3a – Constructional drawing for guard electrodes (two required)
1,5
Dimensions in millimetres
ø52
ø8,2
A
ø44,8
ø44,8
B
ø8,2
ø52
ø4
M8
IEC
Key
A insulating material
B brass
1 two M8 brass nuts for rods
two M8 × 10 brass screws with ∅ 4 mm holes for foam-filled tubes
Figure 3b – Constructional drawings for parts A and B
Figure 3 – Constructional drawings for guard electrodes and parts
6 6
1,2 1,2
– 16 – IEC 60855-1:2016  IEC 2016
Dimensions in millimetres
ø16
ø11
M8
M8
ø25
ø20
+0,1
+0,1
ø16
–0
ø11
–0
ø8,2 IEC
ø8,2
ø52
ø52
IEC
IEC
Figure 4a – For 10 mm diameter solid rod Figure 4b – For 15 mm diameter solid rod
Dimensions in millimetres
ø40,1
ø33
M8
M8
ø22 ø29
ø49
ø42
+0,1
ø40,1
–0
+0,1
ø33
–0
ø29,2
ø22,2
ø52
ø52
IEC
IEC
Figure 4c – For 32 mm diameter foam-filled tube Figure 4d – For 39 mm diameter foam-filled tube
5 15
4,9
18 5
5 15
4,9
Dimensions in millimetres
ø65,2
ø52,2
M8
M8
ø37
ø37
ø75
ø61
+0,1
+0,1
ø65,2
–0
ø52,2
–0
ø37,2
ø37,2
IEC
IEC
Figure 4e – For 51 mm diameter foam-filled tube Figure 4f – For 64 mm diameter foam-filled tube

Dimensions in millimetres
ø78,5
M8
ø37
ø87
+0,1
ø78,5
–0
ø37,2
IEC
Figure 4g – For 77 mm diameter foam-filled tube
Key
1 brass electrode
2 ∅ 4 mm hole for banana plug
3 insulating support
Figure 4 – Drawings for guard electrode parts
according to test piece diameters
4,9
4,9
4,9
– 18 – IEC 60855-1:2016  IEC 2016
5.4.2.1.3 Tests before exposure to humidity
After at least 24 h in the ambient atmosphere of the test area, the current I is measured at an

alternating voltage of 100 kV rms at power frequency applied between the electrodes for
1 min. The maximum current and the phase angle ϕ between current and voltage are

recorded.
5.4.2.1.4 Tests after exposure to humidity
The test pieces shall be placed for 168 h in a conditioning chamber and subjected to a
temperature of 23 °C and a relative humidity of 93 % according to Table 2 of IEC 60212:2010.
At the end of this 168 h period, the test pieces shall remain in an atmosphere of 93 % relative
humidity and be tested upon return to the ambient temperature of the test area. After the test
pieces have been lightly wiped with a dry cloth, the current I and phase angle ϕ are

2 2
measured under the same conditions as I and ϕ
.
1 1
The test piece shall be located in the same position in relation to earth; for both tests, the
high voltage end shall remain the same.
5.4.2.1.5 Test results
Before exposure to humidity:
• the phase angle ϕ measured shall be higher than 80°;
• the current I measured shall not exceed the values given in Table 2.
Table 2 – Maximum current I before exposure to humidity
Solid rod Foam-filled tube
Diameter (mm)
10 15 32 39 51 64 77
10 10 10 12 15 20 25
Maximum current I (µA rms)
The test shall be considered as passed if after exposure to humidity the current I is lower

than 2 I .
If I is greater than 2 I but lower than I + 40 µA, the test shall also be considered as passed
,
2 1 1
if the phase angle between voltage and current is higher than 50° for foam-filled tubes and
40° for solid rods.
In no case shall I be greater than I + 40 µA.

2 1
5.4.2.2 Alternative tests in case of foam-filled tubes and solid rods having completed
the production phase
5.4.2.2.1 Alternative dry test
An example of a suitable test arrangement is given in Figure 5.

Dimensions in millimetres
100 kV
A
300 300
C
B
D
IEC
Key
A insulating table
B foam-filled tube or solid rod to be tested
C stranded wire electrodes not less than 5 mm width
D metallic support
Figure 5 – Alternative dielectric test under dry condition –
Example of a typical test arrangement
The foam-filled tubes and solid rods shall be subjected to an alternating voltage of 100 kV rms
at power frequency applied between electrodes 300 mm apart, for 1 min. The AC voltage shall
be initially applied at a low value and gradually increased at a constant rate-of-rise of
approximately 5 kV/s until the test voltage level is reached. The test period shall be
considered to start at the instant the specified voltage is reached.
The test shall be considered as passed if the foam-filled tubes and solid rods fulfil the
following:
• no flashover, no sparkover or puncture;
• no visual sign of tracking or erosion on the surface;
• no perceptible temperature rise of the foam-filled tube or solid rod estimated by bare hand.
5.4.2.2.2 Alternative test after exposure to immersion
At the production stage, it is not possible to perform the test of 5.4.2.1.4 which requires a long
duration conditioning not compatible with the production stage.
The manufacturer shall perform the test as follows:

– 20 – IEC 60855-1:2016  IEC 2016
• the test set-up shall be the one of 5.4.2.1;
• the conditioning is carried out according to the following.
Before the test, each test piece of 300 mm length shall be prepared by cleaning with
isopropanol (CH -CH(OH)-CH ) and then dried in air at room temperature for a period of not
3 3
less than 15 min.
The test pieces shall be conditioned by total immersion for 24 h in a tank of tap water with a
minimum conductivity of 500 µS/cm corresponding to a maximum resistivity of 20 Ω·m, at
20 °C.
At the end of this conditioning period, the test pieces shall be lightly wiped with a clean dry
lint-free cloth, and the ends of the test pieces covered with conducting adhesive tape. The
test pieces shall be tested upon return to room temperature in the test area.
5.4.3 Wet test
5.4.3.1 Type test
5.4.3.1.1 General test conditions
Before the test, each test piece shall be prepared by cleaning with isopropanol (CH -CH(OH)-
CH ) and then dried in air at room temperature for a period of not less than 15 min.
The electrodes shall be made of an aluminium or copper soft wire 3 mm to 4 mm in diameter,
encircling the test piece with three or four turns, as shown in Figure 6a. The electrodes shall
be placed symmetrically on the test piece and spaced 1 m apart (see Figure 6b). The fixing
support shall be placed at the lower part of the test piece. The high voltage electrode shall be
placed at the upper end of the test piece.
The surface of the electrode should not be oxidized, and if a treatment against oxidization is
applied, it should not modify the characteristics of the water streaming on the test piece.
The test assembly shall comply with Figure 6b. The test piece shall be inclined at an angle of
45° from the vertical. A voltage of 100 kV rms at power frequency shall be applied between
the electrodes for 1 h. The AC voltage shall be initially applied at a low value and gradually
increased at a constant rate-of-rise of approximately 5 kV/s until the test voltage level is
reached. The test period shall be considered to start at the instant the specified voltage is
reached.
5.4.3.1.2 Precipitation characteristics
The wet test shall be carried out in accordance with the standard wet test procedure
described in IEC 60060-1 except for the average and the beginning of the precipitation:
• average precipitation rate in vertical and horizontal directions: 1,0 mm/min to 1,5 mm/min;
• resistivity of collected water corrected to 20 °C: 100 Ω·m ± 15 Ω·m;
• precipitation shall commence immediately when the voltage is applied.
Precipitation shall be such that the water falling near the test piece shall be at a 90° angle to
the test piece, as shown in Figure 6b.
The temperature of the water shall be similar to the temperature of the test area.
As the ambient temperature can change faster than the temperature of the water, when the
temperature is measured a deviation of 3 °C is allowed.

IEC
Key
1 aluminium or copper soft tie wire; 3 to 4 turns, 3 mm to 4 mm diameter
2 electrode fixed by adhesive tape
3 test piece
4 earthing brass braid; 10 mm cross area
Figure 6a – Details of electrode arrangement

45°
45°
IEC
Key
1 high voltage electrode
2 electrode spacing, 1 m
3 rain direction
4 1 m minimum height fixing support
Figure 6b – Typical test arrangement
Figure 6 – Wet test
– 22 – IEC 60855-1:2016  IEC 2016
5.4.3.1.3 Test results
The test shall be considered as passed if the following conditions are met:
• no flashover during the test;
• no sparkover or puncture;
• no visual sign of tracking or erosion on the surface;
• no temperature rise greater than 7 °C, relative to the initial test piece temperature, on any
spot from 10 cm to the high voltage electrode to 10 cm from the earth electrode on the
surface of the test piece at the end of the test period. The temperature measurement shall
take place no more than 2 min after completion of the test.
An infrared camera can be used to measure the temperature of the surface. The camera
should be calibrated for the test object prior to use.
5.4.3.2 Alternative means for insulating foam-filled tubes and solid rods having
completed the production phase
There is no alternative test for checking the conformity with the associated requirement (for
instance, some tests could be destructive). Nevertheless, the manufacturer shall prove that he
has followed the same documented manufacturing procedure with identical components as for
the type-tested product.
5.5 Mechanical tests
5.5.1 Bending test
5.5.1.1 Type test
A foam-filled tube 2,50 m long or a solid rod 2 m long shall be placed between two supports
consisting of pulleys (Figure 7) with the following distance d between the axes:
• 0,50 m for solid rods;
• 1,50 m for 32 mm diameter foam-filled tubes;
• 2 m for 39 mm diameter foam-filled tubes or larger.
At the centre of the span, a vertical force F shall be applied to a leather or fabric strap, 50 mm
± 2,5 mm wide, which is placed on the foam-filled tube or solid rod.

d
ƒ
S
F
IEC
Key
S strap
Figure 7a – Bending test assembly
Dimensions in millimetres
ø35
r = 40
a
IEC
Section a-a
Key
1 foam-filled tube under test
2 pulley
Figure 7b –
...