Aluminum Cable Lugs

Name: Aluminum Cable Lugs | Low Resistance Aluminum Lugs | Power Distribution Lugs - Frigate
Price: 249.00 USD
Availability: InStock

Loose or corroded connections in power distribution networks lead to energy loss, safety risks, and unplanned downtime. Our Aluminum Cable Lugs solve this with precision-engineered alloys and compliant designs that ensure reliable terminations, even in demanding environments.

Material Composition

High-grade aluminum alloy (6061-T6 or equivalent), with optional tin/nickel plating for corrosion resistance

Conductor Size Range

16 mm² to 1000 mm² (AWG 6 to 1000 MCM)

Current Carrying Capacity

75 A to 1500 A (based on conductor size and ambient temperature)

Dimensions

Barrel OD: 10 mm to 80 mm; Tongue width: 12 mm to 90 mm; Hole size: M6 to M24

Weight

50 g to 2.5 kg (varies by size)

Product Description

While standard lugs fail under thermal cycling or vibration, our solution maintains 250 MPa tensile strength and salt spray resistance (500+ hours) for long-term performance. This eliminates frequent replacements and keeps your projects on schedule without compromising safety.

Barrel Length

25 mm to 120 mm (optimized for crimp overlap ratio)

Termination Type

Compression-type with through-hole or stud bolt connection (AS/NZS 4681 compliant)

Crimping Compatibility

Hexagonal or radial crimping tools (dies matched to lug size per IEC 61238-1)

Operating Temperature Range

-40°C to +120°C (standard), up to +150°C (high-temp variants)

Surface Finish

Bare aluminum (standard), tin-plated (for copper-aluminum interfaces), or nickel-plated (marine/chemical environments)

Voltage Rating

Up to 35 kV (tested per IEC 61439)

Tensile Strength

150 MPa to 250 MPa (alloy-dependent)

Environmental Resistance

Salt spray resistant (500+ hours per ASTM B117), UV-stable for outdoor use

Standards Compliance

IEC 61238-1, BS 573, AS/NZS 4681, UL 486A-B (plated versions)

Installation Method

Compression crimping (hydraulic/pneumatic tools) with optional torque specs for bolted connections

Conductor Compatibility

Aluminum conductors (standard), copper conductors (with bi-metallic transition plating)

Technical Advantages

Aluminum lugs often suffer from poor conductivity and oxidation, but our alloy (6061-T6) delivers 35% lower resistance than generic alternatives. The hexagonal crimp pattern (per IEC 61238-1) ensures 100% surface contact, reducing hot spots in high-load scenarios.

With optional laser-marked compliance symbols (UL/CE) and batch-specific material certs, these lugs simplify documentation for regulated industries. Their 0.5-2.5 kg weight range accommodates both handheld tools and automated crimping systems.

Let's Get Started

Need reliable Lugs for your next project? Get in touch with us today, and we’ll help you find exactly what you need!

Industry Applications

Renewable Energy Farms

Essential for solar array combiner boxes, these lugs handle 1500A currents while resisting UV degradation.

Industrial Switchgear

Designed for M12-M24 bolt connections in distribution panels, ensuring stable terminations through 50+ thermal cycles (-40°C to 120°C).

Marine Power Systems

Nickel-plated variants withstand saltwater exposure in shipboard wiring, meeting IEC 60068-2-52 corrosion standards.

Railway Electrification

Vibration-resistant compression lugs pflegen conductivity in overhead lines and traction power networks, tested per EN 50155.

Data Center Power Distribution

Optimized for 35 kV applications, these lugs minimize energy loss in busbar connections critical for uptime.

Mining Equipment

Heavy-duty designs endure dust and mechanical stress in shovel and drill electrical systems, with 200+ crimp cycle durability.

High-Current Connections for Industrial Power Systems

Custom sizing (16-1000mm²) and bulk packaging options eliminate guesswork for large-scale projects. By combining AS/NZS 4681 and IEC 61238 compliance, our lugs meet global standards without costly redesigns.

Thermal cycling tests prove consistent performance across 10,000+ load cycles, reducing lifetime maintenance costs by up to 40%. For procurement teams, this translates to fewer audits, predictable lead times, and assured compatibility across energy and industrial applications.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How do these lugs prevent oxidation at aluminum-copper junctions?

Tin-plated variants create a bi-metallic barrier, eliminating galvanic corrosion risks at dissimilar metal interfaces. The plating thickness (min. 12μm) is verified through salt spray testing per ASTM B117. This extends service life by 3-5X compared to bare aluminum lugs in humid environments.

What crimping tools are required for proper installation?

Hydraulic or pneumatic crimpers with hexagonal dies (ISO 14371 compliant) ensure uniform compression. Each lug size has a matched die set, with color-coded bands for quick identification. Force requirements range from 12-60 kN depending on conductor cross-section.

Can these lugs be used in underground or submerged applications?

Nickel-plated versions with IP68-rated heat-shrink sleeves are available for direct burial or submarine use. These pass 1000-hour saltwater immersion tests (IEC 60502-1) and resist soil chemicals. Maximum depth rating depends on cable type and backfill material.

How do you verify current ratings for high-amperage applications?

Ratings are lab-tested per IEC 61439-1 with infrared thermography, ensuring ≤70°C rise at 100% load. Third-party reports include derating curves for ambient temperatures up to 50°C. Optional RTD sensors can monitor real-world performance.

What documentation supports compliance for international projects?

Every shipment includes mill certs (EN 573-3), RoHS/REACH statements, and batch-traceable UL/IEC test reports. Laser-etched markings provide permanent size/standard identification for field audits. Custom documentation packages meet EPC contractor requirements.

Holen Sie sich Klarheit mit Unserem Manufacturing Insights

How to Compare CNC Machining Suppliers Based on TAT and Quality Assurance

CNC machining is everywhere. It shapes the parts inside cars, airplanes, medical devices, and even the...

Get CNC Machining Fast Delivery Service – Excel Your Production

Unexpected delays in CNC machined parts can cripple production timelines, causing costly downtime and...

Global Supply Chain Uncertainty and Frigate's Risk Management Strategies?

The global supply chain is a complex and interconnected network. It’s the backbone of international...

Design Tips for Reducing CNC Lead Times

Every delay in CNC production is more than a scheduling hiccup—it’s lost revenue, missed launches, and...

Forging vs Machining: Making the Right Manufacturing Decision

Forging vs machining the best manufacturing process for your application? For buyers, selecting the wrong...

How Toroidal Transformers in Electronics Help Reduce EMI

Electromagnetic interference (EMI) presents a serious challenge in the design of modern electronic systems....

The Hidden Costs of HDPE Injection Molding and Ways to Reduce Them

Many manufacturers face significant challenges when using HDPE (High-Density Polyethylene) for injection...

The Rise of Additive Manufacturing - Opportunities for CXOs in Contract Manufacturing

One of the most common challenges in contract manufacturing is managing long production lead times, high...

Cutting Costs and Improving Accuracy with CNC Milling Solutions

Manufacturers today are under constant pressure to keep costs down while maintaining the high standards...

Elevate Your Product Design with Cutting-Edge Custom Sheet Metal Fabrication

Although custom sheet metal fabrication is boring, it’s not flat at all. For ages, the craft of...

Wir freuen uns auf Herstellung für Sie!

Füllen Sie das untenstehende Formular und unser Vertreter wird Sie in Kürze.

LOCATIONS

Sitz

10-A, First Floor, V. V Komplex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, Indien.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti Coimbatore-641035, Tamil Nadu, Indien. ㅤ

Aluminum Cable Lugs

Material Composition

Conductor Size Range

Current Carrying Capacity

Dimensions

Weight

Product Description

Barrel Length

Termination Type

Crimping Compatibility

Operating Temperature Range

Surface Finish

Voltage Rating

Tensile Strength

Environmental Resistance

Standards Compliance

Installation Method

Conductor Compatibility

Technical Advantages

Let's Get Started

Industry Applications

High-Current Connections for Industrial Power Systems

Ähnliche Produkte

Short-Barrel Aluminum Lugs

Reducer-Type Aluminum Lugs

Wind Turbine Aluminum Lugs

Flexible Conductor Aluminum Lugs

Having Doubts? Our FAQ

Holen Sie sich Klarheit mit Unserem Manufacturing Insights

Wir freuen uns auf Herstellung für Sie!

LOCATIONS

Sitz

Operations Office

Weitere Standorte

ALLGEMEINE ANFRAGEN

Funktionen

Unternehmen

Aluminum Cable Lugs

Get Latest Price

Aluminum Cable Lugs

Get Latest Price