Electrical Safety Matting: BS EN 61111 Guide for UK Facilities

Every year, about 1,000 workplace electrical accidents are reported to the HSE. Around 30 prove fatal. Many happen during routine work on switchgear, substations and high voltage equipment. Electrical safety matting to BS EN 61111 provides a key layer of protection for workers in these dangerous settings.

This guide covers what facilities managers, safety officers and electrical engineers need to know. You will learn how to specify, select and maintain electrical insulating matting that meets UK rules.

Understanding BS EN 61111: The Governing Standard

BS EN 61111:2009 (the same as IEC 61111:2009) is the main standard for electrical insulating matting. It applies to matting used in live working tasks. The standard sets out performance needs, test methods and classes. These ensure matting gives proper protection against electric shock.

The standard covers elastomeric floor coverings used as extra protection near electrical gear. Note that insulating matting is classed as auxiliary equipment. This means it adds to primary safety measures but does not replace them. For more on the international standard, see our IEC 61111 compliance guide.

Key Requirements of BS EN 61111

The standard sets out needs across several areas:

Dielectric Properties: Matting must show good electrical resistance. It must withstand proof voltages much higher than the working voltage. Each class is tested at voltages 2 to 3 times the rated working level.

Physical Properties: The rules cover thickness, tensile strength and elongation at break. They also cover ozone resistance. These ensure the matting keeps its protective traits over time.

Surface Traits: The standard needs slip-resistant surfaces. These often have ribbed or studded profiles. It also defines what surface defects are allowed.

BS EN 61111 Classification: Choosing the Right Class

The standard defines five classes of electrical insulating matting. Each class is rated for different maximum working voltages. Picking the right class is vital for proper protection.

Class	Max Working Voltage	Proof Test Voltage	Typical Thickness	Common Uses
0	1,000 V AC	10,000 V	3 mm	Low voltage boards, domestic setups
1	7,500 V AC	20,000 V	3 mm	Medium voltage switchgear, industrial substations
2	17,000 V AC	30,000 V	4 mm	High voltage gear, utility substations
3	26,500 V AC	40,000 V	4-5 mm	Extra high voltage setups
4	36,000 V AC	50,000 V	5 mm	Transmission substations, major plants

How to Pick the Required Class

The rule is simple: the matting class must be rated for a voltage equal to or greater than your equipment’s nominal voltage.

For a 400V three-phase board, Class 0 (rated to 1,000V) works fine. For an 11kV substation, you need at least Class 2 (rated to 17,000V). If unsure, go one class higher for extra safety.

Note that proof test voltages are much higher than working voltages. Class 1 matting rated at 7,500V is actually tested to 20kV. This gives a big safety margin.

Material Specs: What Makes Good Electrical Matting

Not all rubber gives proper electrical insulation. BS EN 61111 matting uses specially made elastomers with high dielectric strength.

EPDM Rubber

EPDM (Ethylene Propylene Diene Monomer) rubber is the top choice for electrical insulating matting. EPDM has the best dielectric strength of common elastomers. This makes it ideal for high voltage matting use. Other benefits include:

• Great resistance to ozone, UV and weather
• Temperature range from -40°C to +120°C
• Good resistance to acids, alkalis and water
• Long service life with little wear

Natural Rubber Compounds

Some makers use natural rubber or blends with natural rubber. While these offer good electrical traits, natural rubber resists ozone less well. It also has a narrower temperature range than EPDM.

Materials to Avoid

Nitrile (NBR) rubber is often used for oil-resistant industrial matting. But it has poor dielectric traits and must never be used for electrical safety. Standard SBR rubber also lacks the electrical resistance needed for high voltage protection.

UK Legal Needs: Electricity at Work Regulations 1989

The Electricity at Work Regulations 1989 place legal duties on employers for electrical safety. Several rules relate directly to insulating matting use.

Regulation 4 requires that all systems be built and kept to prevent danger. This includes proper insulation and shock protection.

Regulation 13 states that proper steps shall be taken to prevent danger when working on dead equipment. Insulating matting forms part of these steps.

Regulation 14 covers work on or near live conductors. It requires suitable steps to prevent injury. Where live working is needed, insulating matting gives vital protection.

The HSE publication HSG85 “Electricity at Work: Safe Working Practices” gives detailed guidance. It includes advice on using insulating matting and other protective gear.

Where Electrical Safety Matting is Needed

Electrical insulating matting should go wherever workers may need to work on or inspect electrical gear. Key uses include:

Switchboards and Distribution Boards

Main switchboards, distribution boards and motor control centres pose electrical hazards. Risks occur during inspection, upkeep and fault finding. Switchboard matting should cover the full working area in front of the equipment.

Substations

Both indoor and outdoor substations need insulating matting where staff access high voltage gear. This includes transformer areas, switchgear rooms and control panels.

Data Centres and Server Rooms

Modern data centres have lots of electrical kit including UPS systems and power units. The mix of high power and constant running creates big electrical hazards. Many data centre operators specify Class 1 or Class 2 matting for electrical rooms.

Industrial Manufacturing

Factories with their own HV substations or large motor drives need proper matting protection. This matters most in industries with constant production. Electrical work often happens under time pressure in these settings.

Transport Systems

Railway substations, traction power systems and airport electrical gear all need compliant insulating matting. These settings often combine high voltages with tough conditions. They may include outdoor exposure and heavy foot traffic.

Installation Best Practice

Proper installation ensures matting gives its intended protection. It also reduces trip hazards.

Sizing and Position

Matting should extend at least 600mm beyond the edges of the switchgear. This ensures workers stay on the insulating surface even when reaching sideways. For large setups, multiple mats can be placed side by side.

Position matting so it lies flat. Avoid folds, curls or raised edges that could cause trips. On uneven floors, some flexing is fine. But avoid big gaps under the matting.

Securing Methods

Electrical insulating matting is usually loose-laid, not bonded to the floor. But it may need securing to stop movement. Options include:

• Heavy-duty double-sided tape for permanent setups
• Bevelled edges or ramps at mat boundaries to reduce trip risk
• Yellow warning borders to boost visibility

Never use metal fasteners or conductive adhesives. These could reduce the insulating properties.

Environmental Factors

Electrical matting should be kept clean and dry. Oil, grease and conductive dirt can reduce surface resistance. This reduces protection. In dirty settings, set up regular cleaning schedules.

Extreme temperatures can affect the material. EPDM matting works well from -40°C to +120°C. But do not store it in direct sunlight or near heat sources that could cause damage.

Testing and Maintenance Needs

Electrical insulating matting needs regular checks and periodic testing. This confirms it remains fit for use.

Visual Inspection

Before each use, check matting for:

• Cuts, tears or holes that go through the full thickness
• Embedded metal objects (staples, swarf, filings)
• Signs of chemical attack or material wear
• Too much wear, especially on ribbed surfaces
• Surface dirt with conductive materials

Remove any matting that fails visual inspection from service right away.

Periodic Electrical Testing

BS EN 61111 advises periodic proof testing. This confirms matting keeps adequate dielectric strength. Test frequency depends on use, but annual testing is common for matting in regular use.

Testing should be done by competent persons using proper high voltage test gear. Record results and label matting with test dates.

When to Replace

Replace electrical insulating matting when:

• It fails visual inspection for damage or dirt
• It fails periodic electrical testing
• It shows signs of wear (cracking, hardening, surface bloom)
• The test date has expired per site policy
• There is any doubt about its condition

Spec Checklist for Buying

When specifying electrical insulating matting, include these needs:

1. Compliance Statement: BS EN 61111:2009 or IEC 61111:2009 compliance with the right class
2. Voltage Rating: Working voltage equal to or above your maximum system voltage
3. Material: EPDM or equivalent elastomer with documented dielectric properties
4. Dimensions: Length, width and thickness for your use case
5. Surface Profile: Ribbed or studded for slip resistance
6. Test Certification: Test certificates confirming proof test results
7. Traceability: Maker details and batch ID for quality assurance

Related Safety Measures

Electrical insulating matting is one part of a full electrical safety plan. Use it with:

Insulating Gloves: BS EN 60903 compliant gloves rated for the working voltage

Insulating Tools: VDE certified tools with insulated handles

Safe Systems of Work: Written procedures including isolation, locking off and proving dead

Training: Competent persons trained in electrical safety and protective gear use

Arc Flash Protection: Where arc flash risk assessments show high hazard levels, specify arc-rated PPE per IEEE 1584 calculations

Cost Factors

Electrical insulating matting is a modest investment compared to other electrical safety measures. Typical costs range from £30 to £150 per square metre. The price depends on class and thickness.

When looking at costs, consider:

• Higher classes cost more but may be needed for compliance
• EPDM matting lasts longer than natural rubber options
• Test certificates add cost but provide vital compliance proof
• Budget for replacing worn or damaged matting

The cost of matting is tiny compared to electrical accident costs. These can include deaths, serious injuries, HSE action and lost production.

Summary

Electrical safety matting to BS EN 61111 provides vital protection for staff working on high voltage gear. Correct specification means knowing the class system, picking the right voltage ratings and ensuring proper setup and upkeep.

For UK facilities, following the Electricity at Work Regulations 1989 needs a full approach to electrical safety. This includes, but goes beyond, providing insulating matting.

When specifying electrical matting, always check the voltage rating matches your equipment. Verify BS EN 61111 compliance. Set up inspection and testing schedules to keep protection throughout the matting’s service life.