Bronze Mechanical Connectors — Cast & Machined Bronze Connectors

Jamnagar Brass Components designs and manufactures bronze mechanical connectors for electrical power distribution, utility infrastructure, overhead line hardware, and industrial electrical applications. Our bronze connectors combine the corrosion resistance, conductivity, and mechanical strength of engineered bronze alloys with precision machining and casting to deliver reliable electrical connections in harsh environments. We export to US utilities, electrical OEMs, distributors, and engineering contractors.

Bronze Alloys Used for Mechanical Connectors

Alloy Name	UNS (USA)	EN (Europe)	BS (UK)	IS (India)	Key Properties
LG2 Bronze	C83600	CC491K	LG2	LTB-2	Excellent castability, corrosion resistant
Gunmetal (85-5-5-5)	C83600	CC491K	LG2/G1	LTB-1	High strength, electrical grade
Silicon Bronze	C65100	CW116C	—	—	High strength, weldable, marine grade
Phosphor Bronze	C51000	CW451K	PB102	—	Spring-grade, fatigue resistant
Aluminium Bronze	C62300	CW307G	AB1	—	Very high strength, seawater resistant

Types of Bronze Mechanical Connectors We Manufacture

Bronze Multi-Tap Connectors

Multi-tap bronze connectors with 2, 4, or 6 taps for connecting multiple tap conductors to a main run conductor without cutting. Used on overhead lines and in transformer substations. Available in LG2 bronze with bronze set-screws.

Bronze Compression Connectors

Cast and machined bronze compression sleeves and connector bodies for crimp connection to copper and aluminium conductors. Designed for use on bare overhead conductors (ACSR, AAC, AAAC) and underground cable terminations.

Bronze Clamp-Type Connectors

Bolted clamp connectors in LG2 or gunmetal bronze for distribution transformers, substations, and switchgear. Available in single-bolt and double-bolt versions, for conductor sizes from 10 mm² to 630 mm².

Bronze Parallel Groove (PG) Connectors

Parallel groove connectors in cast bronze with silicon bronze or stainless steel bolts, for joining two parallel conductors. Compliant with ASTM B 317 and IEC 61284 test requirements for overhead line connectors.

Bronze Dead-End Connectors

Anchor-type dead-end mechanical connectors for terminating bare overhead conductors at pole-top insulators and strain towers. Cast LG2 bronze body with high-tensile bronze or stainless fasteners.

Applications of Bronze Mechanical Connectors

• Overhead distribution and transmission line hardware
• Transformer substation connections
• Underground cable jointing and termination
• Renewable energy (solar and wind farm) AC distribution
• Railway traction overhead equipment (OHE)
• Mining and industrial power distribution
• Marine and offshore electrical systems
• Utility and rural electrification projects

Why Choose Jamnagar Brass Components for Bronze Connectors?

• Proven alloys — LG2, gunmetal, and silicon bronze sourced with full chemistry certs
• IEC and ASTM awareness — designs reference IEC 61284, ASTM B 317, and IEEE Std 837
• In-house sand and gravity die casting — fast pattern development and low tooling cost
• Precision CNC machining — all contact surfaces machined to ensure low contact resistance
• ISO 9001:2015 certified — full inspection and QC reports on every order
• Custom designs — we develop new connector designs from your sketch or specification
• Competitive export pricing — significant cost advantage for US utility procurement
• Testing support — can arrange third-party pull-out and contact resistance testing

Frequently Asked Questions — Bronze Mechanical Connectors

Q1: What is the most common bronze alloy for electrical mechanical connectors?

LG2 bronze (C83600, also known as gunmetal 85-5-5-5) is the most widely specified alloy for cast bronze connectors in power distribution. It combines 15 percent IACS electrical conductivity, excellent atmospheric and seawater corrosion resistance, high castability with low porosity, and decades of proven service in overhead line hardware. Silicon bronze (C65100) is preferred for wrought machined connector bodies requiring higher tensile strength above 380 MPa.

Q2: What conductor sizes do your bronze mechanical connectors accommodate?

Our standard range covers conductors from 10 square mm (AWG 8) up to 630 square mm (approximately 1250 kcmil). Connector bodies for larger conductors up to 1200 square mm can be developed on request. We supply connectors designed for copper conductors, aluminium conductors, and bi-metallic copper to aluminium connections.

Q3: Are your bronze connectors suitable for bi-metallic copper to aluminium connections?

Yes. We offer bi-metallic connectors with a tin-coated aluminium or copper-plated aluminium contact face on the aluminium conductor side to prevent galvanic corrosion at the copper to aluminium interface. The bronze connector body provides structural support and the copper side termination. Proper bi-metallic design is essential where aluminium ACSR conductors connect to copper busbars.

Q4: Can you supply bronze connectors to IEC 61284 or ASTM B 317?

Yes. We design connectors with reference to IEC 61284 (overhead line fittings, requirements and tests) and ASTM B 317 (aluminium-base mechanical connectors). We can arrange third-party mechanical pull-out testing and electrical resistance testing at accredited laboratories to generate type test certificates for customers requiring formal compliance documentation for utility or EPC contractor requirements.

Q5: What is the electrical conductivity of LG2 bronze and does it affect connector performance?

LG2 bronze has approximately 15 percent IACS conductivity, compared to 100 percent for copper. For a connector body of similar cross-section, this means higher resistance than a copper body. However, connector bodies are designed with generous cross-sections and short current paths so that the total connector resistance remains within IEC 61238-1 and IEEE 837 limits. The corrosion resistance and mechanical robustness of bronze justify its use over pure copper for most overhead and substation connector applications.

Q6: What types of overhead line connectors do you manufacture?

We manufacture parallel groove (PG) connectors, multi-tap connectors, H-frame connectors, dead-end anchor clamps, and compression connector bodies in LG2 and silicon bronze. These are used on bare overhead conductor systems including AAC (all aluminium conductor), ACSR (aluminium conductor steel reinforced), and hard-drawn copper conductor lines at distribution voltages from 11 kV to 400 kV.

Q7: Do your bronze connectors come with bolts and fasteners?

Yes. We supply matching silicon bronze bolts, nuts, and spring washers with all bolted bronze connectors. Silicon bronze fasteners prevent galvanic corrosion between connector body and fixings in outdoor environments, provide high proof stress suitable for the torque values required in electrical connections, and have a proven 30 to 50 year outdoor service life matching the connector body.

Q8: What is the working temperature range for LG2 bronze connectors?

LG2 bronze connectors can be used continuously from minus 40 degrees Celsius up to 150 degrees Celsius without significant loss of mechanical or electrical properties. Short-circuit temperature rise is limited by conductor heating rather than connector material. For high-temperature applications above 150 degrees Celsius such as near transformer terminals with forced oil cooling, silicon bronze or aluminium bronze with higher temperature ratings may be specified.

Q9: Can you develop custom bronze connector designs from customer drawings?

Yes. Custom connector development is a core capability at Jamnagar Brass Components. We accept customer sketches, 2D engineering drawings, or 3D CAD files (STEP or IGES) and develop production patterns for sand casting or dies for gravity die casting. First-article samples are provided for dimensional and electrical approval before series production. Typical new product development time is 4 to 8 weeks from approved drawing to first samples.

Q10: What quality certifications and documentation do you provide with bronze connectors?

Every shipment includes: ISO 9001:2015 Certificate of Conformance, Material Test Certificate confirming alloy chemistry per ASTM B584 or BS EN 1982 for the bronze alloy, dimensional inspection report on sample pieces, and packing list with piece count and weight. Third-party inspection by SGS, Bureau Veritas, or TUV is available on request. We can also provide REACH and RoHS compliance declarations.