Brass Terminal Bars
Comprehensive Overview of High-Performance Brass Terminal Bars
We are a premier manufacturer and global supplier of precision-engineered Brass Terminal Bars, serving the electrical distribution, power panel, and industrial control industries with reliable, high-conductivity solutions. Our terminal bars are manufactured from premium C26000 Cartridge Brass (70/30 Brass), renowned for its excellent electrical conductivity, superior mechanical properties, and outstanding corrosion resistance. These critical electrical components are designed to provide secure, low-resistance connections for multiple circuits in distribution boards, switchgear, control panels, and power distribution systems. With advanced manufacturing capabilities including precision extrusion, CNC machining, milling, and electro-tin plating processes, we deliver brass terminal bars that exceed international standards for safety, performance, and durability in demanding electrical applications.
Brass Terminal Bars – Reliable Power Distribution Solutions
Brass Terminal Bars are essential electrical components designed to distribute power, provide common connection points, and manage circuit neutral/ground connections in electrical systems. These bars provide a robust platform for connecting multiple conductors, ensuring proper current distribution and maintaining system stability. The superior electrical and mechanical properties of brass make these bars ideal for handling continuous current loads while resisting corrosion, thermal stress, and mechanical wear in various environmental conditions.
Applications of Brass Terminal Bars
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Electrical Distribution Panels: Main and sub-distribution boards in commercial, industrial, and residential facilities
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Power Distribution Systems: Busbar systems for power routing and distribution
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Switchgear Assemblies: LV/MV switchgear and control gear applications
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Motor Control Centers: Power distribution and control circuit termination
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Industrial Control Panels: PLC systems, automation control panels, and machinery control
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Renewable Energy Systems: Solar combiner boxes, wind turbine control panels, inverter connections
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Telecommunications: Power distribution in telecom cabinets, data centers, and server rooms
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Marine Electrical Systems: Marine distribution boards and control panels
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Railway Systems: Control panels and power distribution in rolling stock
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UPS and Power Backup Systems: Uninterruptible power supply and generator control panels
Brass Alloy Specifications for Terminal Bars
| Brass Alloy | UNS Designation | Composition | Key Properties | Applications |
|---|---|---|---|---|
| Cartridge Brass | C26000 | 70% Cu, 30% Zn | Excellent conductivity, good corrosion resistance, superior formability | General purpose electrical distribution, standard terminal bars |
| Free-Cutting Brass | C36000 | 61.5% Cu, 35.5% Zn, 3% Pb | Excellent machinability, good conductivity | Complex custom bar designs, intricate machining |
| Naval Brass | C46400 | 60% Cu, 39.2% Zn, 0.8% Sn | Superior corrosion resistance, high strength | Marine, coastal, high-humidity applications |
| Leaded Brass | C38500 | 57% Cu, 40% Zn, 3% Pb | Excellent machining characteristics | High-volume production of complex bar designs |
Brass Terminal Bar Technical Specifications
| Parameter | C26000 (Cartridge Brass) | C36000 (Free-Cutting Brass) | C46400 (Naval Brass) |
|---|---|---|---|
| Electrical Conductivity (% IACS) | 28% | 26% | 25% |
| Tensile Strength (MPa) | 325 – 410 | 340 – 470 | 380 – 480 |
| Yield Strength (MPa) | 105 – 195 | 125 – 310 | 170 – 240 |
| Thermal Conductivity (W/m·K) | 120 | 115 | 110 |
| Corrosion Resistance | Excellent | Good | Superior |
| Temperature Rating | -40°C to +120°C | -40°C to +120°C | -40°C to +150°C |
Standard Current Ratings: 100A, 125A, 160A, 200A, 250A, 400A, 630A, 800A, 1000A
Bar Profiles: Flat rectangular, square, round, custom extruded shapes
Terminal Types: Screw clamp, bolted, spring clamp, soldered, welded
Mounting Options: DIN rail, direct panel mount, insulated support, busbar insulators
Standards Compliance: IEC 60947, UL 467, UL 1059, ISO 9001, RoHS compliant, REACH compliant
Product Range & Technical Specifications
Standard Terminal Bars
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Construction: High-conductivity C26000 brass with electro-tin plating
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Terminal Capacity: 2-24 poles with standardized spacing
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Mounting: DIN rail (35mm/7.5mm) or direct panel mounting
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Insulation: Optional insulated covers, barriers, and end caps
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Certification: UL/CE certified for global applications
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Finishes: Electro-tin plating, nickel plating, silver plating, bare brass
Heavy-Duty Bus Bars
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Construction: Thicker brass profiles for higher current ratings (400A-1000A)
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Current Rating: 400A to 1000A continuous
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Applications: Main distribution boards, industrial switchgear, power distribution
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Features: Multiple tap points, reinforced mounting, custom drilling patterns
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Cooling: Optional cooling fins, increased surface area designs
Custom Configuration Bars
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Design Flexibility: Custom lengths, hole patterns, tap arrangements, and mounting
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Special Applications: Marine grade, hazardous area, high-vibration, high-temperature
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Branding: Custom markings, color coding, OEM branding, serialization
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Integration: Combined functions (neutral-ground, multiple circuit types)
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Complex Shapes: Custom extruded profiles, complex machining, special contours
Modular Terminal Bar Systems
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System Design: Expandable modular design for flexible configuration
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Installation: Tool-less assembly and DIN rail mounting
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Applications: Growing systems, retrofit applications, modular panel designs
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Benefits: Reduced inventory, flexible system design, easy expansion
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Accessories: End brackets, connectors, markers, covers, partitions
Manufacturing Processes & Quality Control
Our Brass Terminal Bars are manufactured through precision-controlled processes:
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Material Selection: Certified brass strip/bar/rod to required specifications and standards
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Precision Extrusion/Forming: Creating base bar profiles with consistent dimensions
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CNC Machining: Precision milling, drilling, tapping, and contour machining
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Deburring & Edge Radiusing: Comprehensive edge treatment for safety and performance
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Surface Preparation: Degreasing, cleaning, and surface activation
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Electro-Tin Plating: Uniform tin plating for superior corrosion protection and conductivity
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Quality Inspection: 100% dimensional, visual, and mechanical inspection
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Performance Testing: Electrical, thermal, and mechanical validation
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Packaging: Anti-corrosion packaging with proper identification and protection
Quality Assurance Tests:
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Dimensional Verification: 100% check of all critical dimensions, hole patterns, and tolerances
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Thread Gauging: Go/No-Go testing of all threaded elements and tapped holes
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Plating Thickness: X-ray fluorescence testing per ASTM B568 standards
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Conductivity Testing: Eddy current conductivity verification throughout bar length
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Temperature Rise Testing: Thermal performance under rated current and overload conditions
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Pull-Out Force Testing: Terminal screw retention strength and mechanical integrity
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Salt Spray Testing: Corrosion resistance per ASTM B117 (500+ hours minimum)
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Dielectric Testing: Insulation resistance and dielectric strength where applicable
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Material Certification: Full traceability with mill certificates and material test reports
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Short-Circuit Testing: Fault current withstand capability per IEC 60947 standards
Technical Data & Performance Specifications
Current Carrying Capacity & Temperature Rise
| Bar Size (mm) | Cross-Section (mm²) | Continuous Current | Temperature Rise | Cable Size Range | Torque Specification |
|---|---|---|---|---|---|
| 20×5 | 100 | 160A | 45°C | 50-95mm² | 5.0-6.5 Nm |
| 25×5 | 125 | 200A | 50°C | 70-120mm² | 6.0-7.5 Nm |
| 30×5 | 150 | 250A | 55°C | 95-150mm² | 7.0-9.0 Nm |
| 30×10 | 300 | 400A | 60°C | 185-240mm² | 10.0-12.0 Nm |
| 40×10 | 400 | 630A | 65°C | 300-400mm² | 12.0-15.0 Nm |
| 50×10 | 500 | 800A | 70°C | 400-500mm² | 15.0-20.0 Nm |
Electrical Performance Characteristics
| Parameter | Standard Value | Test Method | Compliance Level |
|---|---|---|---|
| Contact Resistance | < 0.2 mΩ per connection | IEC 60947 | Exceeds standards |
| Dielectric Strength | 3000V AC (insulated versions) | IEC 60664-1 | Full compliance |
| Impulse Withstand | 8kV (insulated versions) | IEC 60060-1 | Surge protection rated |
| Short-Circuit Rating | 10kA/1s to 50kA/1s | IEC 60947 | Fault current withstand |
| Insulation Resistance | >1000 MΩ (insulated versions) | IEC 60664-1 | Superior insulation |
| Voltage Drop | < 5mV per 100A per meter | Custom testing | Optimal performance |
Design Features & Benefits
Brass Terminal Bar Advantages
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Superior Conductivity: Optimal current carrying capacity with minimal voltage drop and power loss
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Excellent Corrosion Resistance: Tin plating prevents oxidation and maintains low contact resistance over time
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Thermal Stability: Maintains mechanical and electrical properties across wide temperature ranges
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Mechanical Strength: Robust construction withstands installation stress, vibration, and thermal cycling
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Long-Term Reliability: Maintains electrical properties throughout extended service life
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Environmental Safety: RoHS compliant, recyclable, and environmentally responsible
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Cost-Effective: Optimal balance of performance, durability, and cost compared to copper alternatives
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Easy Machining: Excellent manufacturability for custom designs and complex configurations
Performance Characteristics
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Low Contact Resistance: Ensures efficient current flow and minimal heating at connection points
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Thermal Performance: Excellent heat dissipation under continuous and peak load conditions
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Vibration Resistance: Secure connections in high-vibration environments and mobile applications
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Easy Installation: Clear markings, accessible termination points, and flexible mounting options
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Maintenance-Free: Durable construction requires no periodic maintenance or re-tightening
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Flexible Configuration: Adaptable to various panel layouts and circuit requirements
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Space Efficient: Compact designs maximize panel space utilization
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Scalable Solutions: Modular systems allow for easy expansion and modification
Industry Compliance & Certifications
International Standards Compliance
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IEC 60947-1: Low-voltage switchgear and controlgear – General rules
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UL 467: Grounding and bonding equipment
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UL 1059: Terminal blocks and busbars
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ISO 9001:2015: Quality management systems
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RoHS 3: Restriction of hazardous substances
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REACH: Chemical safety regulations
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IEC 61439: Low-voltage switchgear and controlgear assemblies
Quality Certifications
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ISO 9001:2015: Quality management system certification
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UL Listed: Safety certification for North American markets
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CE Marking: Compliance with European directives
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Test Certificates: Routine production testing documentation
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Material Certifications: Full traceability from raw material to finished product
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RoHS Compliance Certificates: Environmental compliance documentation
Frequently Asked Questions (FAQ)
Q1: Why choose brass terminal bars over copper or aluminum alternatives?
Brass terminal bars offer the optimal balance of conductivity, mechanical strength, and cost-effectiveness. While copper has higher conductivity (approximately 30% better), brass provides superior mechanical properties, better corrosion resistance, excellent machinability, and significantly lower cost. Compared to aluminum, brass offers higher strength, superior contact properties, eliminates galvanic corrosion issues with copper conductors, and maintains stable connections over time without cold flow issues.
Q2: What are the benefits of tin plating on brass terminal bars?
Tin plating provides multiple critical benefits: prevents surface oxidation maintaining low contact resistance over time, enhances corrosion protection particularly in humid and industrial environments, improves solderability for special applications, provides better contact surface for aluminum conductors reducing galvanic corrosion risk, ensures consistent electrical performance throughout product lifespan, and facilitates easier installation and maintenance.
Q3: Can you manufacture custom terminal bar configurations for specific applications?
Yes, we specialize in comprehensive custom terminal bar solutions including special lengths and profiles, custom hole patterns and tap arrangements, unique mounting configurations, integrated functions (combined neutral-ground bars), special markings/color coding/legends, OEM branding and serialization, complex extruded shapes, and application-specific designs for marine, railway, industrial, and special environments. Our engineering team can develop optimized solutions for your specific technical requirements.
Q4: What testing and certification do your brass terminal bars include?
Every production batch undergoes comprehensive testing and certification including dimensional verification to tight tolerances, conductivity testing throughout bar length, temperature rise testing at 1.5x rated current, pull-out force testing of all termination points, salt spray corrosion testing (500+ hours minimum), dielectric strength verification for insulated versions, short-circuit withstand testing per IEC standards, material certification with full traceability, and compliance certification for relevant international standards.
Q5: How do I select the appropriate terminal bar for my electrical panel design?
Selection depends on multiple critical factors: system current requirements (continuous and peak), number of circuits and connection points, available panel space and mounting constraints, environmental conditions (humidity, temperature, corrosive atmosphere), regulatory and standards requirements, future expansion needs, and installation/maintenance considerations. Our technical team provides comprehensive selection support and can recommend optimal solutions based on your specific application parameters and performance requirements.
Why Choose Our Brass Terminal Bars?
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Material Expertise: Deep knowledge of brass metallurgy, electrical properties, and application requirements
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Precision Manufacturing: Advanced extrusion, CNC machining, and plating capabilities with tight tolerances
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Comprehensive Testing: Full electrical, mechanical, thermal, and environmental validation
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Custom Engineering: Tailored solutions for specific OEM requirements and special applications
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Global Certification: Compliance with international standards and safety requirements for worldwide markets
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Technical Support: Comprehensive application engineering, selection assistance, and design optimization
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Quality Assurance: ISO 9001 certified manufacturing with full traceability and documentation
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Competitive Pricing: Cost-effective solutions without quality compromise or performance sacrifice
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Delivery Reliability: Consistent on-time delivery with flexible production scheduling
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Technical Documentation: Complete specifications, test reports, CAD drawings, and installation guides
Call to Action – Contact Us Today
Ensure optimal power distribution and reliable electrical connections with our high-performance brass terminal bars. Contact us for quotations, technical assistance, or application engineering support.
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Request a Quote: Email your specifications and requirements to sales@jambrass.com for prompt, comprehensive quotation
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Technical Consultation: +91-22-43449300 – Speak directly with our electrical components engineering specialists
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Documentation Request: sales@jambrass.com – Request detailed specifications, test certificates, CAD drawings, and application guides
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Office Address: 1406, 14th Floor, Dalamal Tower, Nariman Point, Mumbai – 400021, Maharashtra, India
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Factory Address: Plot 10B, GIDC Industrial Estate, Shanker Tekari, Udyognagar, Jamnagar, Gujarat – 361004
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Samples Available: Contact us for evaluation samples, test reports, and performance demonstrations
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OEM Inquiries: Dedicated support for volume manufacturing, custom solutions, and partnership opportunities
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Emergency Requirements: Expedited production and delivery for urgent project needs
We look forward to providing you with the highest quality brass terminal bars and comprehensive technical support for your electrical distribution, panel building, and power management requirements.
