Comprehensive Technical Overview of Brass Split-Bolt Connectors
We are one of the leading manufacturers and exporters of Brass Split-Bolt Connectors, Electrical Split-Bolt Connectors, and Heavy-Duty Connection Systems from India. We have been supplying high-quality Brass Split-Bolt Connectors, Copper Split-Bolt Connectors, Grounding Split-Bolt Connectors, Utility Split-Bolt Connectors, Insulated Split-Bolt Connectors, Custom Split-Bolt Connectors, and Special Application Brass Split-Bolt Connectors to the world market for many decades. Our state-of-the-art manufacturing facility specializes in producing premium Brass Split-Bolt Connection Systems using advanced copper alloy formulation, precision hot forging, 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 Split-Bolt Connector manufacturing, we serve diverse industries including electrical power distribution, telecommunications infrastructure, railway electrification, industrial grounding systems, renewable energy projects, utility infrastructure, and construction electrical systems. Our expertise encompasses working with various brass alloys including High Conductivity Brass (C26000), Free Cutting Brass (C36000), Naval Brass (C46400), and DZR Brass (CW602N). We manufacture Brass Split-Bolt Connectors in sizes from #14 AWG to 500 MCM, current ratings from 50A to 600A, voltage ratings up to 1000V, maintaining excellent electrical conductivity (minimum 26% IACS), superior corrosion resistance, compliance with UL 486A, IEEE 837, BS 5731, ASTM B16 standards, and reliable performance in various electrical connection applications.
Types of Brass Split-Bolt Connectors
Standard Brass Split-Bolt Connectors
General Purpose Split-Bolt Connectors with U-shaped design and dual-nut configuration, featuring precision-machined threads and secure clamping mechanism. Available in sizes from #14 to 4/0 AWG with current ratings from 50A to 200A. These Universal Connection Devices provide reliable splicing for electrical conductors, grounding electrodes, cable splicing applications, and general electrical installations where secure mechanical and electrical connections are required.
Heavy-Duty Brass Split-Bolt Connectors
High-Capacity Split-Bolt Connectors with reinforced design and increased cross-sectional area, featuring robust construction and enhanced current-carrying capacity. Sizes from 4/0 to 500 MCM with current ratings from 200A to 600A. These High-Current Connectors are essential for main power connections, service entrance splices, transformer terminations, and high-current applications where maximum current carrying capacity and mechanical strength are critical.
Grounding Brass Split-Bolt Connectors
Grounding Specific Split-Bolt Connectors with optimized design for grounding and bonding applications, featuring enhanced conductivity and superior corrosion resistance. These Grounding Connection Devices are crucial for equipment grounding, lightning protection systems, ground grid connections, safety grounding applications, and bonding jumpers where reliable earth continuity is mandatory.
Insulated Brass Split-Bolt Connectors
Non-Conductive Covered Split-Bolt Connectors with integrated insulating sleeves, featuring dielectric protection and safety compliance. These Insulated Connection Devices provide electrical isolation for accessible locations, safety applications, outdoor installations, wet locations, and situations requiring additional electrical protection against accidental contact.
Explosion-Proof Brass Split-Bolt Connectors
Hazardous Area Split-Bolt Connectors with flame-path design and increased safety features, featuring precision-machined threads and secure sealing. These Safety-Rated Connectors are designed for hazardous locations, chemical plants, oil and gas facilities, mining operations, and explosive atmospheres where maximum safety and reliability are required.
Material Specifications & Properties
Brass Alloy Composition & Electrical Properties
| Alloy Type | Composition | Conductivity (% IACS) | Tensile Strength (MPa) | Yield Strength (MPa) | Rockwell Hardness |
|---|---|---|---|---|---|
| High Conductivity Brass C26000 | 70% Cu, 30% Zn | 32% | 325-410 | 130-160 | B75-B82 |
| Free Cutting Brass C36000 | 61.5% Cu, 35.5% Zn, 3% Pb | 26% | 340-420 | 170-200 | B78-B85 |
| Naval Brass C46400 | 60% Cu, 39.25% Zn, 0.75% Sn | 28% | 380-480 | 170-210 | B75-B85 |
| DZR Brass CW602N | 58-60% Cu, 36-38% Zn, 1.6-2.5% Pb | 25% | 400-500 | 180-220 | B80-B90 |
Performance Specifications & Standards
| Parameter | Standard Grade | Heavy-Duty Grade | Marine Grade | Test Standard |
|---|---|---|---|---|
| Current Rating | 50-200A | 200-600A | 100-300A | UL 486A |
| Short Circuit Withstand | 10kA for 1s | 25kA for 1s | 15kA for 1s | IEEE 837 |
| Torque Strength | 15-60 Nm | 40-120 Nm | 20-80 Nm | ASTM E8 |
| Corrosion Resistance | 500 hours | 750 hours | 1000+ hours | ASTM B117 |
| Temperature Rating | -40°C to 120°C | -40°C to 150°C | -40°C to 120°C | IEC 60068 |
Manufacturing Excellence
Advanced Manufacturing Process
Hot Forging Technology: Precision hot forging for superior grain structure and mechanical properties
CNC Machining: Multi-axis machining for precise threads and contact surfaces
Thread Rolling: Cold-forming process for superior thread strength and fatigue resistance
Heat Treatment: Stress relief annealing for optimal mechanical properties
Surface Treatment: Electroplating, passivation, and special coatings
Quality Testing: 100% dimensional, visual, and electrical testing
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, tensile testing, and compression testing
Electrical Testing: Contact resistance measurement and current cycling tests
Performance Validation: Salt spray testing, thermal cycling, and accelerated aging
Technical Specifications & Performance Data
Split-Bolt Connector Specifications & Dimensions
| Connector Size | Conductor Range | Current Rating | Bolt Diameter | Overall Length | Torque Value | Weight |
|---|---|---|---|---|---|---|
| #14 – #8 AWG | 2.5-8.5mm² | 50A | 8mm | 50mm | 15-20 Nm | 45g |
| #6 – #2 AWG | 13.5-33.5mm² | 100A | 10mm | 60mm | 20-30 Nm | 85g |
| 1/0 – 3/0 AWG | 50-85mm² | 150A | 12mm | 70mm | 30-45 Nm | 150g |
| 4/0 – 250 MCM | 120-125mm² | 200A | 16mm | 85mm | 50-70 Nm | 280g |
| 300 – 400 MCM | 150-200mm² | 300A | 20mm | 100mm | 70-100 Nm | 450g |
| 500 MCM | 250mm² | 500A | 24mm | 120mm | 90-120 Nm | 650g |
| 600 MCM | 300mm² | 600A | 27mm | 140mm | 110-150 Nm | 850g |
Electrical Performance Specifications
| Performance Parameter | Standard Value | Enhanced Value | Test Condition |
|---|---|---|---|
| Contact Resistance | <15μΩ | <8μΩ | At 100A DC |
| Temperature Rise | 45°C at rated current | 35°C at rated current | Ambient 25°C |
| Short Circuit Withstand | 10kA for 1s | 25kA for 1s | IEEE 837 Standard |
| Voltage Drop | <2.5mV per 100A | <1.5mV per 100A | Steady State |
| Insulation Resistance | >1000 MΩ | >5000 MΩ | 500V DC |
International Standards & Certifications
Global Compliance & Approvals
UL 486A: Wire connectors and soldering lugs
IEEE 837: Standard for qualifying permanent connections
BS 5731: British standard for electrical connections
ASTM B16: Standard specification for free-cutting brass rod
IEC 61238: Compression and mechanical connectors
RoHS Compliance: Restriction of hazardous substances
Testing & Certification Standards
Short Circuit Testing: UL 486A for fault current withstand capability
Temperature Rise Testing: IEEE 837 for current carrying capacity verification
Mechanical Testing: Torque and tensile strength testing
Environmental Testing: Salt spray and humidity testing per ASTM B117
Material Certification: Mill certificates with full traceability
Industry Applications
Electrical Power Distribution
Service Entrance Connections: Main service conductor splicing and terminations
Transformer Connections: Primary and secondary winding connections
Distribution Line Splices: Overhead and underground conductor splicing
Capacitor Bank Connections: Power factor correction equipment terminations
Telecommunications & Data Centers
Tower Grounding Systems: Communication tower grounding and bonding
Equipment Bonding: Telecom equipment grounding connections
Cable Splicing: Communication and data cable terminations
Lightning Protection: Surge protection system connections and bonding
Industrial & Commercial Applications
Motor Power Connections: Large industrial motor power terminations
Ground Grid Systems: Industrial plant grounding networks
Busbar Connections: Busbar system terminations and splices
Equipment Grounding: Machinery and equipment safety grounding
Installation Guidelines & Maintenance
Professional Installation Procedure
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Conductor Preparation: Clean conductor surfaces using appropriate wire brush
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Connector Selection: Choose appropriate size for conductor range and application
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Conductor Placement: Position conductors properly in U-shaped opening
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Nut Tightening Sequence: Use calibrated torque wrench with specified values in cross pattern
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Contact Verification: Ensure proper contact and uniform pressure distribution
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Final Inspection: Verify installation quality and electrical continuity
Maintenance Best Practices
Regular Inspection: Annual visual inspection and infrared thermal scanning
Torque Verification: Triennial torque check in critical applications
Corrosion Monitoring: Biannual assessment in harsh environments
Contact Resistance Testing: Periodic measurement for critical connections
Preventive Maintenance: Cleaning and re-torquing as per manufacturer recommendations
Frequently Asked Questions
Q1: What are the key advantages of brass split-bolt connectors over other connection methods?
Brass split-bolt connectors offer excellent electrical conductivity, superior corrosion resistance, reusable design, easy installation without special tools, reliable mechanical strength, cost-effectiveness, and proven long-term reliability compared to compression connectors or exothermic welded connections.
Q2: Can brass split-bolt connectors be used for aluminum to copper connections?
Yes, our brass split-bolt connectors are specifically designed for connecting aluminum to copper conductors. The brass material is electrochemically compatible with both metals, and we recommend using antioxidant compound to prevent galvanic corrosion and ensure long-term reliability.
Q3: What is the maximum operating temperature for your split-bolt connectors?
Standard brass split-bolt connectors are rated for continuous operation from -40°C to 120°C. Special high-temperature versions using naval brass can operate up to 150°C, while insulated versions maintain their dielectric properties within specified temperature ranges.
Q4: Do you provide split-bolt connectors with different plating options?
Yes, we offer various plating options including tin plating (3-8μm), silver plating (5-15μm), and nickel plating (5-10μm) to suit different environmental conditions and application requirements. Custom plating specifications are available with minimum order quantities.
Q5: What is the expected service life of your brass split-bolt connectors?
Our brass split-bolt connectors have a service life expectancy of 25+ years in standard applications and 20+ years in harsh environments when properly installed and maintained. Regular maintenance and periodic inspections can extend the service life significantly.
Q6: What testing and certification do you provide with your split-bolt connectors?
We provide comprehensive testing including dimensional verification, mechanical strength testing, electrical performance testing, and environmental testing. Our products are certified to UL 486A, IEEE 837, and other international standards, with full material traceability and test certificates available.
Contact Us Today – Request Quote for Brass Split-Bolt Connectors
Ready to discuss your Brass Split-Bolt Connector requirements for electrical power distribution, grounding systems, telecommunications infrastructure, or custom connection solutions?
Request a Quote: Send your specifications including connector size, conductor range, current rating, plating requirements, 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 connector 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
