T&D CASE STUDY
Driving Improved Whole‑Life Value for UK TNOs
AT A GLANCE
Up to 50% cost saving (application-dependent)
400 kg to 16 kg weight reduction
1 polymeric unit replaces up to 20 glass insulators
Lead times reduced by up to 50%
Facing rising costs, extended lead times, and increasing operational challenges associated with traditional glass insulators, a major UK transmission network operator accelerated its evaluation of alternative technologies already under consideration.
Polymeric insulators offered a flexible and proven solution capable of meeting demanding high-voltage requirements while improving pollution performance, installability, and long-term supply resilience.
However, transitioning from long-established glass technologies required careful validation.
PACE Networks, working alongside Rebosio, supported the operator in addressing key concerns around adoption.
This included developing new installation methodologies, validating safety for field crews, and supporting testing to confirm the technology would not introduce additional wind noise or operational risks.
Through this collaborative process, the operator gained the confidence to progress polymeric insulators from trial evaluation towards wider network application.
Glass insulators have historically been the standard for high-voltage transmission in the UK. However, the operator was increasingly impacted by several compounding issues:
Earlier generations of polymeric insulators had been viewed with caution in the UK due to concerns around brittleness and long-term durability. Although polymeric insulator technology had been widely deployed internationally since the mid-1980s, its adoption on higher-voltage UK transmission networks had progressed at a slower pace.
The operator required strong technical evidence that modern polymeric insulators could perform reliably at 275 kV and 400 kV, not just at lower voltage levels.
PACE Networks introduced Rebosio HTV polymeric insulators, a modern, field-proven alternative designed for high-voltage transmission environments.
Key characteristics of the solution included:
PACE supported the operator through a structured technical evaluation process, drawing on international reference projects and established use across European and global networks. Testing included practical assessments such as walking on tension insulators, as well as the required global and client standards. This helped demonstrate that polymeric insulators could meet UK performance expectations at transmission voltages.
The first project using the solution was approved in October 2022, with on-site deployment beginning in early 2023 following a defined testing and validation period.
Feedback from installation teams was strongly positive. Compared to traditional glass strings, the polymeric solution delivered clear practical advantages:
From an operational perspective, reduced breakage risk and improved resilience supported longer-term asset performance.
While cost benefits varied depending on application and configuration, the polymeric solution delivered cost savings of up to 50% in some scenarios when compared with glass.
Just as importantly, the solution helped address wider supply chain challenges:
This combination of technical, logistical, and commercial benefits made polymeric insulators a viable long-term alternative rather than a short-term solution.
By adopting Rebosio HTV polymeric insulators, the operator was able to:
Reduce dependency on traditional glass insulators
Improve installation efficiency and site safety
Lower logistics, handling, and storage demands
Strengthen resilience against supply chain disruption
Technical support and quality products from a long established European Manufacturer
Confidently deploy polymeric technology at transmission voltages
The project marked an important step in modernising network infrastructure while maintaining strict performance and safety standards.
PACE Networks acted as both technical partner and supply specialist, supporting the transition from legacy materials to modern polymeric technology.
Their role included:
This collaborative approach helped ensure confidence at every stage.
contact pace for more information on the testing
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