HT inline lugs

Maintaining steady power ensures your operations avoid disruptions from weak connections. Our HT Inline Lugs handle big current with high-grade copper or aluminum bodies, meeting your needs for uniform energy delivery. 

Material Composition

High-conductivity electrolytic copper (C10100) with tin/silver plating options

Conductor Size Range

25 mm² to 1000 mm² (4/0 AWG to 2000 kcmil)

Current Carrying Capacity

200A to 2500A (at 40°C ambient temperature)

Dimensions

Barrel OD: 12mm to 65mm; Length: 50mm to 200mm (size-dependent)

Weight

150g to 2500g (varies by size and material)

Product Description

Loose joints can lead to costly downtime and repairs. We design these units with strong crimped barrels to provide balanced power flow, supporting your operational stability and cost management. 

Barrel Length

30mm to 150mm (extended options available)

Termination Type

Through-bolt or parallel-groove clamp design

Crimping Compatibility

Hydraulic crimping only (6-60 ton presses)

Operating Temperature Range

-40°C to 150°C (short-term peaks to 200°C)

Surface Finish

Hot-dip tinned standard; silver-plated (99.9%) optional

Voltage Rating

11kV to 33kV (IEC 61238-1 Class A compliant)

Tensile Strength

Minimum 220 MPa (copper body); 170 MPa (joint strength)

Environmental Resistance

UV-resistant for outdoor use; IP68-rated waterproof versions

Standards Compliance

IEC 61238-1 Class A, BS 4579, ASTM B105, DIN 46235

Installation Method

Hydraulic crimping with certified dies; torque-controlled bolting

Conductor Compatibility

Compatible with ACSR, AAAC, and copper stranded conductors

Technical Advantages

High-tension setups require lugs that manage wide conductor sizes and endure heat effectively. Our HT Inline Lugs support strong tensile strength and operate in tough conditions, ensuring functional performance under varying loads. 

Power drops can disrupt your processes and increase upkeep costs. These units feature tin plating and inline tension hold, maintaining balanced operation to support your production needs. 

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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

Wind Farm Collector Systems

Maintains oxidation-free connections in offshore arrays, surviving salt spray and vibration at 150m hub heights. 

Substation Busbar Extensions

Handles 2500A continuous current in switchgear interconnections, with ceramic-filled options for arc-flash zones. 

Traction Power Networks

Vibration-resistant through-bolt design preserves contact pressure under 25Hz railway harmonic loads. 

Industrial Plant Feeders

Silver-plated versions reduce contact resistance in aluminum-to-copper transitions at furnace transformers. 

Solar Farm Combiners

UV-stabilized insulation prevents degradation in desert environments with 0.5% annual resistance drift. 

Tunnel Lighting Circuits

IP68-rated waterproofing ensures moisture immunity in underground high-bay installations. 

Stability Via Secure Power Delivery

Production systems benefit from lugs that optimize energy use and reduce wear for your needs. Our HT Inline Lugs offer solid crimping fits and function with high heat dissipation rate, enabling functional fit and sustained performance in your setups. 

Steady power connections enhance your ability to maintain output without frequent adjustments. High durability in these lugs supports your cost-saving goals, ensuring long-term capacity in multiple applications. 

HT inline lugs

Having Doubts? Our FAQ

Check all our Frequently Asked Question

What certifications do your HT Inline Lugs carry for utility-scale projects?

Our lugs are fully compliant with IEC 61238-1 Class A requirements for high-voltage connections, including rigorous short-circuit testing. They carry additional certifications from BS 4579 and ASTM B105 for material quality and mechanical performance. All products ship with complete test reports and material certificates for seamless project documentation.

How do your lugs address aluminum conductor oxidation issues?

We offer hot-dip tinned versions with 12μm minimum plating thickness to create an oxidation barrier on aluminum conductors. The tin layer maintains stable contact resistance below 20μΩ even after prolonged exposure to humidity. For extreme environments, silver-plated options provide superior galvanic compatibility. 

What makes your lugs suitable for offshore wind applications?

Our marine-grade HT Inline Lugs feature IP68 waterproofing and salt spray resistance exceeding 1000 hours per ASTM B117. The copper alloy formulation resists stress corrosion cracking in high-vibration tower environments. Custom insulation kits are available for submerged cable terminations.

Can your lugs accommodate different conductor types in the same joint?

Dual-rated versions are available for mixed copper/aluminum applications with bi-metallic transition plates. These incorporate Belleville washers to maintain constant contact pressure despite differential thermal expansion. All transition joints undergo 2000-cycle thermal aging tests.

What quality documentation accompanies bulk orders?

Every shipment includes batch-specific material certs (including mill test reports), full dimensional inspection records, and short-circuit test certificates. Laser-etched traceability codes provide permanent identification for all components. Project-specific documentation packages can include witness test reports for major installations.

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LOCATIONS

Global Sales Office

818, Preakness lane, Coppell, Texas, USA – 75019

Registered Office

23, 6th West Street, Balaji Nagar, Kattur,  Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.

Operations Office

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

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HT inline lugs

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

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