Comprehensive Technical Overview of Bronze Stirrup Clamps
We are one of the leading manufacturers and exporters of Bronze Stirrup Clamps, Electrical Stirrup Clamps, and Heavy-Duty Support Clamps from India. We have been supplying high-quality Bronze U-Bolt Clamps, Stirrup Type Clamps, Busbar Support Clamps, Electrical Conductor Clamps, Support Clamps for Busbars, and Custom Bronze Stirrup Clamps to the world market for many decades. Our state-of-the-art manufacturing facility specializes in producing premium Bronze Electrical Support Systems using advanced copper alloy formulation, precision sand casting, hot forging technology, CNC machining, heat treatment processes, thread rolling, surface finishing, automated assembly, mechanical testing, and comprehensive quality assurance systems. With over three decades of global experience in Bronze Stirrup Clamp manufacturing, we serve diverse industries including electrical power distribution, industrial busbar systems, substation equipment, switchgear manufacturing, railway electrification, renewable energy projects, and heavy electrical infrastructure. Our expertise encompasses working with various bronze alloys including Gunmetal Bronze (BS 1400 LG2), Phosphor Bronze (BS 1400 PB4), Aluminum Bronze (BS 1400 AB2), and High-Strength Bronze Alloys. We manufacture Bronze Stirrup Clamps in sizes from M8 to M24, conductor support capacities from 50mm² to 1000mm², current ratings from 200A to 2000A, maintaining temperature ratings from -40°C to 150°C, excellent mechanical strength, compliance with IEC 62271, IS 5621, ANSI C119.4, ASTM B283 standards, and reliable performance in demanding electrical support applications.
Types of Bronze Stirrup Clamps
Standard U-Bolt Stirrup Clamps
Heavy-Duty U-Bolt Clamps with forged bronze U-bolt and precision-machined saddle, featuring uniform pressure distribution and superior mechanical strength. Available in various thread sizes from M8 to M20 with conductor support capacities from 50mm² to 400mm². These Universal Support Clamps provide reliable support for busbar installations, conductor mounting, equipment connections, and electrical distribution systems where secure mechanical support is required.
Double-Bolt Stirrup Clamps
Enhanced Security Stirrup Clamps with dual-bolt design for increased clamping force, featuring wider saddle surface and balanced pressure distribution. Current ratings from 400A to 1200A with robust bronze construction. These High-Pressure Clamps are essential for heavy busbars, main conductors, critical connections, and high-current applications where maximum clamping security is necessary.
Insulated Stirrup Clamps
Non-Conductive Support Clamps with bronze core and insulated coating, featuring dielectric strength and mechanical durability. Available with various insulation materials including epoxy coating and plastic covers. These Isolated Support Clamps are designed for insulated bus systems, safety applications, corrosive environments, and special installations where electrical isolation is required.
Adjustable Stirrup Clamps
Versatile Support Clamps with sliding design for variable conductor sizes, featuring adjustable saddle and flexible configuration. Available in multiple size ranges with single or double bolt configurations. These Multi-Size Clamps solve compatibility issues in retrofit projects, system modifications, temporary installations, and variable conductor applications.
High-Temperature Stirrup Clamps
Thermal Resistant Stirrup Clamps with special bronze alloy construction, featuring enhanced temperature capability and thermal stability. Temperature range from -40°C to 200°C with maintained mechanical properties. These Elevated Temperature Clamps are crucial for furnace connections, heating systems, high-temperature equipment, and thermal process applications.
Material Specifications & Properties
Bronze Alloy Composition & Mechanical Properties
| Alloy Type | Composition | Conductivity (% IACS) | Tensile Strength (MPa) | Yield Strength (MPa) | Elongation (%) |
|---|---|---|---|---|---|
| Gunmetal Bronze LG2 | 85% Cu, 5% Zn, 5% Sn, 5% Pb | 25% | 240-300 | 120-150 | 20-25 |
| Phosphor Bronze PB4 | 90% Cu, 10% Sn, 0.2% P | 18% | 350-450 | 200-250 | 15-20 |
| Aluminum Bronze AB2 | 85% Cu, 10% Al, 3% Fe, 2% Ni | 20% | 600-750 | 300-400 | 12-18 |
| High-Strength Bronze | 88% Cu, 8% Sn, 2% Zn, 2% Pb | 22% | 400-500 | 180-220 | 18-22 |
Performance Specifications & Ratings
| Parameter | Standard Range | Heavy-Duty Range | Test Standard |
|---|---|---|---|
| Current Rating | 200A – 800A | 800A – 2000A | IEC 62271 |
| Mechanical Strength | 8kN – 25kN | 25kN – 60kN | IS 5621 |
| Clamping Force | 2kN – 15kN | 15kN – 40kN | ANSI C119.4 |
| Temperature Rating | -40°C to 120°C | -40°C to 200°C | ASTM B283 |
| Corrosion Resistance | 1000+ hours salt spray | 2000+ hours salt spray | ASTM B117 |
Manufacturing Excellence
Advanced Manufacturing Process
Sand Casting Technology: Precision sand casting for complex geometries and superior metal structure
Hot Forging Process: 600-ton forging presses for U-bolt manufacturing with superior grain flow
CNC Precision Machining: 5-axis CNC machining centers maintaining tolerances of ±0.02mm
Thread Rolling: Cold-forming thread rolling for increased strength and superior surface finish
Heat Treatment: Solution treatment and aging for optimal mechanical properties
Surface Treatment: Tin plating, passivation, or natural bronze finish
Quality Assurance Protocols
Material Certification: Mill certificates with full chemical composition analysis
Dimensional Control: CMM inspection with statistical process control
Mechanical Testing: Tensile testing, compression testing, and torque testing
Metallurgical Testing: Microstructure analysis and hardness testing
Performance Validation: Salt spray testing, thermal cycling, and accelerated aging
Technical Specifications & Performance Data
Mechanical Strength & Clamping Capacity
| Clamp Model | Thread Size | Conductor Size | Clamping Force | Mechanical Strength | Torque Value | Weight |
|---|---|---|---|---|---|---|
| BSC-U-8 | M8 | 50-95mm² | 2-4kN | 8kN | 15-20Nm | 0.25kg |
| BSC-U-10 | M10 | 70-120mm² | 4-6kN | 12kN | 25-30Nm | 0.35kg |
| BSC-U-12 | M12 | 95-185mm² | 6-9kN | 16kN | 40-50Nm | 0.55kg |
| BSC-U-16 | M16 | 150-240mm² | 9-15kN | 25kN | 70-80Nm | 0.85kg |
| BSC-U-20 | M20 | 185-300mm² | 15-25kN | 35kN | 100-120Nm | 1.25kg |
| BSC-D-12 | M12 | 120-185mm² | 12-18kN | 30kN | 40-50Nm | 0.75kg |
| BSC-D-16 | M16 | 185-300mm² | 18-30kN | 45kN | 70-80Nm | 1.10kg |
Electrical Performance & Current Ratings
| Clamp Size | Current Rating | Voltage Rating | Contact Resistance | Temperature Rise |
|---|---|---|---|---|
| M8 | 200A | 1kV | <20μΩ | 45°C |
| M10 | 400A | 3.3kV | <15μΩ | 50°C |
| M12 | 630A | 6.6kV | <12μΩ | 55°C |
| M16 | 800A | 11kV | <10μΩ | 60°C |
| M20 | 1000A | 22kV | <8μΩ | 65°C |
| M24 | 1200A | 33kV | <6μΩ | 70°C |
International Standards & Certifications
Global Compliance & Approvals
IEC 62271: High-voltage switchgear and controlgear
IS 5621: Indian standard for copper and copper alloy busbars
ANSI C119.4: Electric connectors – connectors for use between aluminum-to-aluminum conductors
ASTM B283: Standard specification for copper and copper-alloy die forgings
IEC 61439: Low-voltage switchgear and controlgear assemblies
Testing & Certification Standards
Short Circuit Testing: IEC 62271 for short circuit withstand capability
Temperature Rise Testing: IEC 61439 for current carrying capacity
Mechanical Testing: IS 5621 for mechanical strength validation
Environmental Testing: IEC 60068 for environmental conditions
Industry Applications
Electrical Power Systems
Busbar Support Systems: Main and distribution busbar mounting and support
Switchgear Installations: Circuit breaker and disconnector bus connections
Substation Equipment: Transformer and reactor busbar connections
Distribution Panels: LV and MV distribution board conductor support
Industrial Applications
Manufacturing Plants: Heavy equipment power connections and busbar systems
Process Industries: Chemical and petrochemical plant electrical systems
Mining Operations: High-current equipment connections and power distribution
Steel Plants: Furnace connections and heavy power distribution
Renewable Energy
Solar Power Plants: DC and AC distribution system conductor support
Wind Farms: Generator connections and power collection systems
Hydroelectric Plants: Generator terminals and switchyard connections
Installation Guidelines & Maintenance
Professional Installation Procedure
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Surface Preparation: Clean conductor and clamp surfaces using appropriate methods
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Clamp Selection: Verify clamp size matches conductor dimensions and current requirements
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Assembly Sequence: Position saddle and U-bolt in correct orientation
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Torque Application: Use calibrated torque wrench with specified torque values
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Alignment Check: Ensure proper conductor alignment and clamp positioning
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Final Inspection: Verify installation quality and mechanical security
Maintenance Best Practices
Regular Inspection: Annual visual inspection and torque verification
Electrical Testing: Triennial contact resistance measurement
Corrosion Monitoring: Biannual corrosion assessment in harsh environments
Performance Verification: Periodic thermographic inspection
Replacement Schedule: 25-year recommended service life with proper maintenance
Frequently Asked Questions
Q1: What are the advantages of bronze stirrup clamps over steel clamps?
Bronze stirrup clamps offer superior corrosion resistance, excellent electrical conductivity, non-magnetic properties, and better compatibility with copper and aluminum conductors. They prevent galvanic corrosion and provide reliable long-term performance in electrical applications.
Q2: Can these clamps be used for both copper and aluminum conductors?
Yes, our bronze stirrup clamps are suitable for both copper and aluminum conductors. The bronze material is electrochemically compatible with both metals, preventing galvanic corrosion and ensuring reliable connections.
Q3: What is the maximum temperature rating for your bronze stirrup clamps?
Standard bronze stirrup clamps are rated for continuous operation up to 120°C, while our high-temperature versions can withstand up to 200°C. Special alloys are available for even higher temperature applications.
Q4: Do you provide insulated versions for safety applications?
Yes, we offer insulated stirrup clamps with various coating options including epoxy resin, powder coating, and plastic covers. These provide electrical isolation and enhanced safety in critical applications.
Q5: What is the expected service life of your bronze stirrup clamps?
Our bronze stirrup clamps have a minimum service life expectancy of 25+ years when properly installed and maintained, with proven performance in various industrial and utility applications worldwide.
Q6: What testing do you perform on finished clamps?
We perform 100% dimensional inspection, thread gauge verification, mechanical strength testing, and sample destructive testing. Additionally, we conduct type tests including temperature rise, short circuit, corrosion resistance, and environmental testing.
Contact Us Today – Request Quote for Bronze Stirrup Clamps
Ready to discuss your Bronze Stirrup Clamp requirements for electrical power systems, industrial applications, busbar support, or custom electrical clamping solutions?
Request a Quote: Send your specifications including clamp type, thread size, conductor dimensions, 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 clamp 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
