Comprehensive Technical Overview of Brass Conduit Plugs
We are one of the leading manufacturers and exporters of Brass Conduit Plugs, Electrical Conduit Plugs, and Cable Gland Accessories from India. We have been supplying high-quality Brass Conduit Plugs, Threaded Conduit Plugs, Waterproof Conduit Plugs, Blank Plugs, Electrical Insulating Plugs, Custom Conduit Plugs, and Special Application Brass Plugs to the world market for many decades. Our state-of-the-art manufacturing facility specializes in producing premium Brass Conduit Plug Systems using advanced copper alloy formulation, precision sand casting, hot forging technology, CNC machining, heat treatment processes, thread rolling, surface finishing, automated assembly, electrical testing, and comprehensive quality assurance systems. With over three decades of global experience in Brass Conduit Plug manufacturing, we serve diverse industries including electrical power distribution, industrial automation, building services, marine electrical systems, hazardous area installations, telecommunications infrastructure, and outdoor electrical applications. Our expertise encompasses working with various brass alloys including Free Cutting Brass (C36000), Architectural Brass (C38500), Naval Brass (C46400), Leaded Brass (C35300), and DZR Brass (CW602N). We manufacture Brass Conduit Plugs in sizes from PG7 to PG48, metric threads from M12 to M63, and NPT threads from 1/2″ to 2″, maintaining excellent corrosion resistance, good electrical conductivity, compliance with IEC 62444, BS 4568, ANSI C80.3, ASTM B16 standards, and reliable performance in various electrical conduit applications.
Types of Brass Conduit Plugs
Standard Threaded Brass Conduit Plugs
General Purpose Conduit Plugs with parallel threads for sealing unused conduit entries, featuring precise threading and secure sealing design. Available in sizes from PG7 to PG36 with various thread types. These Universal Conduit Plugs provide reliable sealing for electrical enclosures, control panels, junction boxes, and general electrical installations where unused conduit entries need protection.
Waterproof Brass Conduit Plugs
Sealed Conduit Plugs with integrated rubber gaskets or O-rings, featuring weatherproof design and environmental protection. These Weatherproof Plugs are essential for outdoor installations, marine applications, wet locations, and harsh environments where moisture and dust protection is critical for unused conduit entries.
Insulated Brass Conduit Plugs
Non-Metallic Sealed Plugs with integrated insulating material, featuring dielectric protection and electrical safety. These Insulated Plugs provide electrical isolation for sensitive equipment, grounding applications, hazardous areas, and situations requiring additional electrical protection in unused conduit entries.
Brass Conduit Blank Plugs
Solid Conduit Plugs with completely sealed design, featuring maximum protection and permanent closure. These Permanent Plugs are crucial for abandoned conduit entries, permanent closures, safety applications, and situations requiring complete sealing where future access is not required.
Quick-Release Brass Conduit Plugs
Tool-Free Conduit Plugs with quick-install design, featuring hand-tightenable operation and reusable capability. These Easy-Access Plugs are designed for temporary closures, maintenance access points, test points, and applications requiring frequent access to conduit entries.
Material Specifications & Properties
Brass Alloy Composition & Mechanical Properties
| Alloy Type | Composition | Tensile Strength (MPa) | Yield Strength (MPa) | Elongation (%) | Rockwell Hardness |
|---|---|---|---|---|---|
| Free Cutting Brass C36000 | 61.5% Cu, 35.5% Zn, 3% Pb | 340-420 | 170-200 | 25-35 | B78-B85 |
| Architectural Brass C38500 | 57-60% Cu, 35.5-40.5% Zn, 2.5-3.5% Pb | 380-450 | 160-190 | 30-40 | B70-B80 |
| Naval Brass C46400 | 60% Cu, 39.25% Zn, 0.75% Sn | 380-480 | 170-210 | 25-35 | B75-B85 |
| DZR Brass CW602N | 58-60% Cu, 36-38% Zn, 1.6-2.5% Pb | 400-500 | 180-220 | 20-30 | B80-B90 |
Performance Specifications & Standards
| Parameter | Standard Grade | Heavy-Duty Grade | Marine Grade | Test Standard |
|---|---|---|---|---|
| Thread Engagement | 3-6 full threads | 5-8 full threads | 4-7 full threads | ISO 228 |
| Torque Strength | 5-60 Nm | 15-100 Nm | 10-80 Nm | IEC 62444 |
| IP Rating | IP44 | IP66 | IP68 | IEC 60529 |
| Corrosion Resistance | 500 hours | 750 hours | 1000+ hours | ASTM B117 |
Manufacturing Excellence
Advanced Manufacturing Process
Sand Casting Technology: Precision sand casting for solid plug construction
Hot Forging Process: 400-ton forging presses for high-strength components
CNC Machining: Precision threading and external profile finishing
Thread Rolling: Cold-forming process for superior thread strength
Heat Treatment: Stress relief annealing for optimal mechanical properties
Surface Treatment: Electroplating, passivation, and special coatings
Quality Testing: 100% dimensional, visual, and thread inspection
Quality Assurance Protocols
Raw Material Testing: Spectrochemical analysis for alloy composition verification
Dimensional Control: CMM inspection with statistical process control
Thread Verification: Go/No-Go gauge testing for thread accuracy
Mechanical Testing: Torque testing, compression testing, and pressure testing
Seal Testing: Pressure and vacuum testing for waterproof plugs
Performance Validation: Salt spray testing, thermal cycling, and IP testing
Technical Specifications & Performance Data
Conduit Plug Specifications & Dimensions
| Plug Size | Thread Type | Major Diameter | Thread Pitch | Plug Height | Weight (g) | IP Rating |
|---|---|---|---|---|---|---|
| PG7 | PG Thread | 12.5mm | 1.5mm | 8mm | 5 | IP44 |
| PG9 | PG Thread | 15.2mm | 1.5mm | 9mm | 8 | IP44 |
| PG11 | PG Thread | 18.6mm | 1.5mm | 10mm | 12 | IP44 |
| PG13.5 | PG Thread | 20.4mm | 1.5mm | 11mm | 16 | IP44 |
| PG16 | PG Thread | 22.5mm | 1.5mm | 12mm | 22 | IP54 |
| PG21 | PG Thread | 28.3mm | 1.5mm | 14mm | 35 | IP54 |
| PG29 | PG Thread | 37.0mm | 1.5mm | 16mm | 65 | IP66 |
| PG36 | PG Thread | 47.0mm | 1.5mm | 18mm | 110 | IP66 |
Environmental & Performance Specifications
| Performance Parameter | Standard Value | Waterproof Value | Test Condition |
|---|---|---|---|
| Water Ingress Protection | IP44 | IP68 | IEC 60529 |
| Pressure Resistance | 0.5 bar | 2.0 bar | 30 minutes |
| Temperature Range | -25°C to 105°C | -40°C to 120°C | Continuous Operation |
| UV Resistance | 500 hours | 1000 hours | ISO 4892 |
| Chemical Resistance | Good | Excellent | IEC 60695 |
Thread Standards & Compatibility
International Thread Specifications
| Thread Standard | Thread Angle | Pitch | Applications | Regions |
|---|---|---|---|---|
| PG Thread | 80° | 1.5mm | General Electrical | Europe, Asia |
| Metric Thread | 60° | 1.0-2.0mm | Industrial Equipment | Worldwide |
| NPT Thread | 60° | Tapered | Plumbing, Hazardous | North America |
| G Thread | 55° | 1.0-2.0mm | Instrumentation | Worldwide |
Surface Finishes & Coatings
Available Finishes & Specifications
| Finish Type | Thickness | Salt Spray Resistance | Applications | Standards |
|---|---|---|---|---|
| Natural Brass | N/A | 96 hours | Indoor, General | – |
| Nickel Plated | 5-15μm | 200-300 hours | Industrial, Marine | ISO 1456 |
| Chrome Plated | 10-20μm | 300-500 hours | Marine, Food | ISO 6158 |
| Tin Plated | 3-10μm | 150-200 hours | Electrical, HVAC | ISO 2093 |
| Yellow Chromate | 0.5-2μm | 200 hours | Decorative, Architectural | ISO 10546 |
International Standards & Certifications
Global Compliance & Approvals
IEC 62444: Cable glands and conduit fittings
BS 4568: Specification for steel conduit and fittings
ANSI C80.3: Steel rigid conduit
ASTM B16: Standard specification for free-cutting brass rod
UL 514B: Conduit, tubing, and cable fittings
RoHS Compliance: Restriction of hazardous substances
Testing & Certification Standards
Thread Testing: Gauging per ISO 228
Corrosion Testing: Salt spray per ASTM B117
IP Testing: Ingress protection per IEC 60529
Pressure Testing: Seal integrity per ISO 5208
Material Certification: Mill certificates with full traceability
Industry Applications
Electrical Power Distribution
Distribution Boards: Sealing unused conduit entries in electrical panels
Control Panels: Protecting spare conduit entries in automation systems
Switchgear: Sealing unused ports in power distribution equipment
Motor Control Centers: Closing unused conduit entries in MCCs
Industrial Automation
PLC Enclosures: Sealing spare conduit entries for control systems
Sensor Junction Boxes: Protecting unused entries in sensor networks
Machine Tool Enclosures: Sealing conduit entries in machinery
Process Control Panels: Closing unused ports in industrial processes
Building Services
Commercial Buildings: Sealing conduit systems in structures
Hospital Installations: Protecting medical equipment connections
Data Centers: Sealing unused conduit entries in server rooms
Lighting Control Panels: Closing spare conduit entries
Installation Guidelines & Maintenance
Professional Installation Procedure
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Thread Inspection: Verify thread compatibility and condition
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Plug Selection: Choose appropriate size and type for application
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Seal Preparation: Ensure sealing surfaces are clean and undamaged
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Thread Engagement: Start threads carefully to prevent cross-threading
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Torque Application: Use appropriate tools with specified torque values
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Final Inspection: Verify proper seating and secure installation
Maintenance Best Practices
Regular Inspection: Visual inspection for corrosion, damage, or loosening
Thread Maintenance: Periodic cleaning and anti-corrosion treatment
Seal Replacement: Replace seals in waterproof plugs every 2-3 years
Torque Verification: Check tightness in critical applications
Replacement Schedule: 20+ year service life with proper installation
Frequently Asked Questions
Q1: What are the advantages of brass conduit plugs over plastic?
Brass conduit plugs offer superior mechanical strength, better corrosion resistance, higher temperature tolerance, non-aging properties, excellent UV resistance, and maintain sealing performance over a wider temperature range compared to plastic plugs.
Q2: Can brass conduit plugs be used in hazardous areas?
Yes, our brass conduit plugs are suitable for hazardous areas due to their non-sparking characteristics, corrosion resistance, and reliable sealing properties. For specific hazardous area certifications, we can provide plugs with appropriate documentation.
Q3: What is the IP rating of your waterproof conduit plugs?
Our standard waterproof conduit plugs achieve IP66 rating, while our premium versions achieve IP68 rating when properly installed. This ensures protection against powerful water jets and prolonged immersion where required.
Q4: Do you provide custom conduit plugs for special applications?
Yes, we specialize in custom conduit plug manufacturing including special thread types, unique sizes, custom sealing requirements, and special features. Minimum order quantities apply for custom specifications.
Q5: What is the expected service life of your brass conduit plugs?
Our brass conduit plugs have a service life expectancy of 20+ years in standard applications and 15+ years in harsh environments when properly installed and maintained, depending on the specific alloy and environmental conditions.
Q6: What testing do you perform on finished conduit plugs?
We perform 100% dimensional inspection, thread gauge verification, visual examination, and sample mechanical testing. Additionally, we conduct corrosion testing, IP rating testing, pressure testing, seal integrity testing, and material verification.
Contact Us Today – Request Quote for Brass Conduit Plugs
Ready to discuss your Brass Conduit Plug requirements for electrical installations, industrial automation, marine applications, or custom conduit sealing solutions?
Request a Quote: Send your specifications including plug size, thread type, sealing requirements, material grade, finish, quantity, and application details to sales@jambrass.com for a detailed quotation within 24 hours.
Technical Support: Email your application requirements or technical drawings for plug selection guidance, material recommendation, and certification assistance.
Call Us: +91-22-43449300 / +91-22-43449323 (Monday-Friday, 9:00 AM – 6:00 PM IST)
Office Address: 1406, 14th Floor, Dalamal Tower, Nariman Point, Mumbai – 400021, Maharashtra, INDIA
Factory Address: Plot 10B, GIDC Industrial Estate, Shanker Tekari, Udyognagar, Jamnagar, Gujarat, India – 361004
Contact Person: Mr. Mehul Vora
Email: sales@jambrass.com
