Comprehensive Technical Overview of Brass Split Bolts
We are one of the leading manufacturers and exporters of Brass Split Bolts, Electrical Split Bolts, and Conductor Connection Systems from India. We have been supplying high-quality Brass Split Bolts, Copper Split Bolts, Grounding Split Bolts, Utility Split Bolts, Custom Split Bolts, and Special Application Brass Split Bolts 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, surface finishing, automated assembly, electrical testing, and comprehensive quality assurance systems. With over three decades of global experience in Brass Split Bolt manufacturing, we serve diverse industries including electrical power distribution, telecommunications, railway electrification, industrial grounding systems, renewable energy projects, and utility infrastructure. 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 Bolts in sizes from #14 to 500 MCM, current ratings from 50A to 500A, maintaining excellent electrical conductivity, 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 Bolts
Standard Brass Split Bolts
General Purpose Split Bolts with U-shaped design and dual-nut configuration, featuring precision threads and secure clamping. Available in sizes from #14 to 4/0 with current ratings from 50A to 200A. These Universal Connection Bolts provide reliable splicing for electrical conductors, grounding electrodes, cable splicing, and general electrical applications where secure mechanical and electrical connections are required.
Heavy-Duty Brass Split Bolts
High-Capacity Split Bolts with reinforced design and increased cross-section, featuring robust construction and higher current ratings. Sizes from 4/0 to 500 MCM with current ratings from 200A to 500A. These High-Current Bolts are essential for main power connections, service entrances, transformer terminations, and high-current applications where maximum current carrying capacity is critical.
Grounding Brass Split Bolts
Grounding Specific Split Bolts with optimized design for grounding applications, featuring enhanced conductivity and corrosion resistance. These Grounding Connection Bolts are crucial for equipment grounding, lightning protection systems, ground grid connections, and safety grounding applications where reliable earth continuity is mandatory.
Insulated Brass Split Bolts
Non-Conductive Covered Split Bolts with insulating sleeves, featuring dielectric protection and safety compliance. These Insulated Connection Bolts provide electrical isolation for accessible locations, safety applications, outdoor installations, and situations requiring additional electrical protection.
Special Configuration Brass Split Bolts
Custom Design Split Bolts with unique configurations for specific applications, featuring engineered solutions and specialized designs. These Application-Specific Bolts address unique challenges in special projects, retrofit applications, overseas requirements, and proprietary equipment connections.
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 | 200-500A | 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 |
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
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 Specifications & Dimensions
| Bolt Size | Conductor Range | Current Rating | Bolt Diameter | Overall Length | Torque Value | Weight |
|---|---|---|---|---|---|---|
| #14 – #8 | 2.5-8.5mm² | 50A | 8mm | 50mm | 15-20 Nm | 45g |
| #6 – #2 | 13.5-33.5mm² | 100A | 10mm | 60mm | 20-30 Nm | 85g |
| 1/0 – 3/0 | 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 |
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 |
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
RoHS Compliance: Restriction of hazardous substances
REACH Compliance: European chemicals regulation
Testing & Certification Standards
Short Circuit Testing: UL 486A for fault current withstand
Temperature Rise Testing: IEEE 837 for current carrying capacity
Mechanical Testing: Torque and tensile strength testing
Environmental Testing: Salt spray and humidity testing
Material Certification: Mill certificates with full traceability
Industry Applications
Electrical Power Distribution
Service Connections: Main service conductor splicing
Transformer Terminations: Primary and secondary connections
Distribution Lines: Overhead and underground conductor splicing
Capacitor Banks: Power factor correction connections
Telecommunications
Tower Grounding: Communication tower grounding systems
Equipment Bonding: Telecom equipment grounding connections
Cable Splicing: Communication cable terminations
Lightning Protection: Surge protection system connections
Industrial Applications
Motor Connections: Large motor power connections
Ground Grid Systems: Industrial plant grounding networks
Busbar Connections: Busbar system terminations
Equipment Grounding: Machinery and equipment safety grounding
Installation Guidelines & Maintenance
Professional Installation Procedure
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Conductor Preparation: Clean conductor surfaces using wire brush
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Bolt Selection: Choose appropriate size for conductor range
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Conductor Placement: Position conductors properly in U-shaped opening
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Nut Tightening: Use calibrated torque wrench with specified values
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Contact Verification: Ensure proper contact and pressure distribution
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Final Inspection: Verify installation quality and electrical continuity
Maintenance Best Practices
Regular Inspection: Annual visual inspection and 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
Replacement Schedule: 25-year recommended service life with proper installation
Frequently Asked Questions
Q1: What are the advantages of brass split bolts over other connection methods?
Brass split bolts offer excellent electrical conductivity, superior corrosion resistance, reusable design, easy installation, reliable mechanical strength, and cost-effectiveness compared to compression connectors or welded connections.
Q2: Can split bolts be used for aluminum to copper connections?
Yes, our brass split bolts are suitable 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.
Q3: What is the maximum temperature rating for your split bolts?
Standard brass split bolts are rated for continuous operation from -40°C to 120°C. Special high-temperature versions using naval brass can operate up to 150°C for specific applications.
Q4: Do you provide split bolts with different thread types?
Yes, we manufacture brass split bolts with various thread types including metric, UNC, UNF, and special threads. Custom thread specifications are available with minimum order quantities.
Q5: What is the expected service life of your brass split bolts?
Our brass split bolts have a service life expectancy of 25+ years in standard applications and 20+ 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 split bolts?
We perform 100% dimensional inspection, thread gauge verification, visual examination, and sample mechanical testing. Additionally, we conduct corrosion testing, current cycling tests, short circuit testing, and material verification for quality assurance.
Contact Us Today – Request Quote for Brass Split Bolts
Ready to discuss your Brass Split Bolt requirements for electrical power distribution, grounding systems, telecommunications, or custom connection solutions?
Request a Quote: Send your specifications including bolt size, conductor range, current rating, thread type, 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 split bolt 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
