Bronze Hotline Clamps, Bronze Hotline Clamps in India
Overview & Usage
Bronze Hotline Clamps are used in overhead power distribution and transmission networks for live-line operations. They provide a safe, secure, and highly conductive connection between a main conductor (run) and a branch/tap conductor—without requiring the line to be de-energized. We are an Indian manufacturer and supplier of Bronze hotline clamps, Aluminum Hotline clamps, Liveline clamps, Bronze taps, Aluminum taps.
They are widely applied in:
- Utilities and power companies for distribution lines.
- Substations and switchyards for tapping busbars.
- Emergency repairs and live maintenance works.
Construction & Design
- Clamp Body: High-strength Bronze casting for mechanical durability and excellent electrical conductivity.
- Keeper / Jaw: Bronze with grooved profile to grip conductors securely.
- Hardware: Heavy-duty Stainless Steel (AISI 304/316) bolts, nuts, and washers for corrosion resistance and long service life.
- Surface Finish: Available plain (natural bronze) or tin/silver plated to enhance conductivity and prevent surface oxidation.
- Design Features:
- Extended jaw width to increase contact area, reducing heating.
- Smooth radius edges to prevent conductor damage.
- Spring washers for vibration resistance and to maintain pressure.
Material Grades
- C83600 (Leaded Red Bronze) – Excellent machinability, standard clamp body alloy.
- C95500 / C95510 (Nickel Aluminum Bronze) – Superior strength and corrosion resistance for heavy duty use.
- C95200 (Aluminum Bronze) – Strong, wear resistant, commonly used for high-tension clamps.
- Stainless Steel 304/316 – For bolts, nuts, washers, and eyebolts.
Typical Sizes & Code Numbers
| Code No. | Run Conductor Range | Tap Conductor Range | Body Material | Hardware | Remarks |
|---|---|---|---|---|---|
| BHC-101 | 16 – 35 mm² | 10 – 25 mm² | Bronze (C83600) | SS 304 | Service taps |
| BHC-102 | 35 – 70 mm² | 16 – 35 mm² | Al-Bronze (C95200) | SS 304 | Medium jumper connections |
| BHC-103 | 70 – 120 mm² | 25 – 70 mm² | Ni-Al Bronze (C95500) | SS 316 | Distribution line |
| BHC-104 | 120 – 240 mm² | 50 – 120 mm² | Bronze + Tin Plated | SS 316 | Substation busbars |
| BHC-105 | 240 – 400 mm² | 70 – 185 mm² | Nickel Al-Bronze | SS 316 | Extra high-voltage / Heavy duty |
(Code numbers are customizable for your product line; “BHC” stands for Bronze Hotline Clamp.)
Performance Features
- High conductivity due to bronze body with optional tin/silver plating.
- Corrosion resistant with stainless steel hardware, suitable for outdoor and coastal environments.
- Uniform pressure ensures secure grip and minimizes cold flow of conductor.
- Compliant with ANSI C119.4 standards for electrical connectors.
- Easy live-line installation with hot-stick compatible design.
Applications & Advantages
- Live-line tapping without power interruption.
- Branching or extending distribution feeders.
- Secure tap connections in substations.
- Long service life with minimal maintenance.
Advantages of Bronze vs. Aluminum clamps:
- Higher mechanical strength and hardness.
- Better wear resistance in repeated tightening/loosening.
- More stable electrical contact under load cycles.
- Naturally more resistant to spark erosion and arcing.