Makers of ZEROflame® Technology

We calculate dip molding speeds and make regular quality checks to ensure our electrical covers are manufactured using the best and safest material on the market, ZEROflame®.

Torch Testing

Flame Testing

Material Testing





Durometer

Shore A

85 to 95


ASTM D149

500 to 600 V/Mil

UL-94-5VA, Edition 6

Self Extinguishing

Pass

ASTM D-412-16

UV 1,000 hrs , no change

Tensile Pass

Elongation Pass

Heat and Humidity

312 hrs 150 dgrs F

Pass, no change

Cold Mandrel

24 hrs 0 dgrs F., 12 mm

Pass

ASTM D4060

Abrasion Resistance

Excellent

Glass Transition

-55 C

Product Testing



Wind Tunnel Testing

120 MPH to 150 MPH

Wet Moving Electrode


Wet Withstand to

38 kV

UV Testing



Test Method:

ASTM D412-16, Method A

Test Conditions:

23±2°C

Conditioning:

3+ hours, 23±2°C

Preparation:

Die cut from sample sent by client

Specimen:

Die C Dumbbell (1 inch gage length)

Cross Head Speed:

20 inches per minute



Sample

Replicate

Width

(inches)

Thickness

(inches)

Tensile

Strength

(psi)

Elongation

at

Break

(%)

DB5340 – As Received

1

0.25

0.0894

1400

160


2

0.25

0.0852

1390

160


3

0.25

0.0854

1390

160


Median

1390

160

Std. Dev.

5.8

0

Requirement

N/A

N/A

Wind Tunnel Test Results

Wind Tunnel Run Log

60” Avian Protection Cover Tested with No Fasteners
/
*SPEED 110 MPH

View the complete KLAP25KE /  K-Series Kit that makes all avian safe at 60 inches. 

Cutout Cover Used by
Large Southern Utility
*SPEED 150 MPH

Deadend Cover
*SPEED 120 MPH

Our Dead End Covers are self-extinguishing, UV resistant, and wind tested up to 150 Mph.

K-Line Cover: Twist due to movement of trunnion clamp.
*SPEED 120 MPH

The KLAP25K Insulator Cover is used today throughout the United States. Made in the USA with ZEROflame® material.

Wedge Tap Cover
Large and Medium
*SPEED 120 MPH

We manufacture Tap Covers to fit polymer and ceramic cutouts.

Wedge Tap Cover Large and Medium Feathered End
*SPEED 120 MPH

We manufacture Tap Covers available with pin or slide closures. 

Quality Control

Quality Control begins when we purchase raw materials and continues through the life of our products.

Our Quality Control assures product consistency, effectiveness, and total customer satisfaction.

All of our products go through multiple inspections before they are shipped.

#1

Material

Proprietary plastisol material ordered, received, inspected */touch point, verified, inventoried.

#2

Machine Operators

Receive order, Inspect molds */touch point – reject or remanufacture, mount onto dip molding system.

#3

Program to Order

• Set machine temperature; check temperature at mold. */touch point

• Set dwell time-measure digital thickness to specification on the mold every five dips. */touch point

• Rejections recorded on Quality Assurance Form.

#4

Remove Product

• Air Pressure Removal

• Cure

• Cold Bath

#5

Secondary Finishing – Final Inspection

*/Touch Point

• Trim, drill, punch, cut and finish product to order specification.

• Match hole, pin and clip alignment.

• Rejections recorded on Quality Assurance Form.

#6

Laser Etched Labeling

• ZEROflame™ / CCI Logo

• Production Date

• Product Code

• Any customer specified data