Bronze Hotline Clamps, Bronze Hotline Clamps in India
Overview & Usage
Bronze Hotline Clamps are used in overhead power distribution and transmission networks for live-line operations. They provide a safe, secure, and highly conductive connection between a main conductor (run) and a branch/tap conductor—without requiring the line to be de-energized. We are an Indian manufacturer and supplier of Bronze hotline clamps, Aluminum Hotline clamps, Liveline clamps, Bronze taps, Aluminum taps.
They are widely applied in:
Utilities and power companies for distribution lines.
Substations and switchyards for tapping busbars.
Emergency repairs and live maintenance works.
Construction & Design
Clamp Body: High-strength Bronze casting for mechanical durability and excellent electrical conductivity.
Keeper / Jaw: Bronze with grooved profile to grip conductors securely.
Hardware: Heavy-duty Stainless Steel (AISI 304/316) bolts, nuts, and washers for corrosion resistance and long service life.
Surface Finish: Available plain (natural bronze) or tin/silver plated to enhance conductivity and prevent surface oxidation.
Design Features:
Extended jaw width to increase contact area, reducing heating.
Smooth radius edges to prevent conductor damage.
Spring washers for vibration resistance and to maintain pressure.
Material Grades
C83600 (Leaded Red Bronze) – Excellent machinability, standard clamp body alloy.
C95500 / C95510 (Nickel Aluminum Bronze) – Superior strength and corrosion resistance for heavy duty use.
C95200 (Aluminum Bronze) – Strong, wear resistant, commonly used for high-tension clamps.
Stainless Steel 304/316 – For bolts, nuts, washers, and eyebolts.
Typical Sizes & Code Numbers
| Code No. | Run Conductor Range | Tap Conductor Range | Body Material | Hardware | Remarks |
|---|---|---|---|---|---|
| BHC-101 | 16 – 35 mm² | 10 – 25 mm² | Bronze (C83600) | SS 304 | Service taps |
| BHC-102 | 35 – 70 mm² | 16 – 35 mm² | Al-Bronze (C95200) | SS 304 | Medium jumper connections |
| BHC-103 | 70 – 120 mm² | 25 – 70 mm² | Ni-Al Bronze (C95500) | SS 316 | Distribution line |
| BHC-104 | 120 – 240 mm² | 50 – 120 mm² | Bronze + Tin Plated | SS 316 | Substation busbars |
| BHC-105 | 240 – 400 mm² | 70 – 185 mm² | Nickel Al-Bronze | SS 316 | Extra high-voltage / Heavy duty |
(Code numbers are customizable for your product line; “BHC” stands for Bronze Hotline Clamp.)
Performance Features
High conductivity due to bronze body with optional tin/silver plating.
Corrosion resistant with stainless steel hardware, suitable for outdoor and coastal environments.
Uniform pressure ensures secure grip and minimizes cold flow of conductor.
Compliant with ANSI C119.4 standards for electrical connectors.
Easy live-line installation with hot-stick compatible design.
Applications & Advantages
Live-line tapping without power interruption.
Branching or extending distribution feeders.
Secure tap connections in substations.
Long service life with minimal maintenance.
Advantages of Bronze vs. Aluminum clamps:
Higher mechanical strength and hardness.
Better wear resistance in repeated tightening/loosening.
More stable electrical contact under load cycles.
Naturally more resistant to spark erosion and arcing.
