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Long-Barrel Copper Lugs

When secure electrical connections are critical for your operations, lugs must deliver unwavering strength without fail. Our Long-Barrel Copper Lugs handle current capacities from 50 A to 1200 A with high-conductivity copper, ensuring consistent power delivery for your systems.

Material Composition

High-conductivity electrolytic copper

Conductor Size Range

2.5 mm² to 400 mm² (AWG 14 to 800 MCM), customizable upon request

Current Carrying Capacity

50 A to 1200 A, depending on conductor size and ambient conditions

Dimensions

Length: 40 mm to 120 mm; Barrel diameter: 6 mm to 30 mm; Stud hole: 6 mm to 16 mm (customizable)

Weight

15 g to 250 g, depending on size and extended barrel length
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Product Description

Weak connections can disrupt processes and increase costs. We design these lugs with extended barrels to provide steady terminations, supporting your need for reliable power and operational control. 

Barrel Length

20 mm to 60 mm, providing extra crimping surface for secure conductor retention

Termination Type

Single-hole stud design; stud sizes from 6 mm (M6) to 16 mm (M16) for robust bolting

Crimping Compatibility

Compatible with hexagonal, indent, or circular crimping tools; hydraulic tools recommended

Operating Temperature Range

-55°C to 150°C, maintaining conductivity under thermal stress

Surface Finish

Bare copper or tin-plated options, enhancing corrosion resistance and contact reliability

Voltage Rating

800 N to 4000 N, ensuring superior mechanical stability due to longer barrel

Tensile Strength

500 N to 3000 N, ensuring mechanical stability post-crimping

Environmental Resistance

IP54 rating; resists oxidation and moisture in controlled indoor/outdoor environments

Standards Compliance

Conforms to IEC 61238-1, UL 486A-486B, and RoHS for safety and performance

Installation Method

Crimp-on only; designed for heavy-duty crimping tools

Conductor Compatibility

Supports stranded or solid copper conductors (Class B to Class K), ideal for larger wires

Technical Advantages

Power delivery needs lugs that maximize strength and handle stress effectively. Our Long-Barrel Copper Lugs offer tensile strength from 800 N to 4000 N and operate from -55°C to 150°C, ensuring effective performance to meet your requirements. 

Loose joints can lead to system failures and downtime. These lugs feature barrel lengths from 20 mm to 60 mm and corrosion-resistant options, maintaining stability to support your operational needs. 

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Industry Applications

Heavy Machinery Systems

Secures cables for motors, ensuring consistent power for production lines. 

Wind Turbine Assemblies

Connects wiring for generators, providing steady current for energy output. 

Industrial Control Panels

Links circuits for controls, delivering consistent flow for system safety. 

Battery Storage Units

Joins cables for batteries, ensuring steady power for energy management. 

Mining Equipment

Fastens wiring for drills, providing consistent strength for harsh conditions. 

Power Distribution Boards

Ties into busbars, delivering steady connections for load stability. 

long-barrel copper lugs

Reliability Beyond Connections

Operational setups excel with lugs that reduce risks and secure power for your needs. Our Long-Barrel Copper Lugs support conductor sizes from 2.5 mm² to 400 mm² and handle voltages up to 35 kV, enabling effective fit and sustained functionality in your systems. 

Strong connections enhance your ability to maintain uptime without added complexity. High durability in Long-Barrel Copper lugs supports your cost-saving goals, ensuring long-term performance in multiple applications.

Long-Barrel Copper Lugs

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Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does your long barrel improve connection strength in my systems?

The extended barrel, ranging from 20 mm to 60 mm, provides more crimping surface for a tighter grip on conductors. This increases tensile strength up to 4000 N, reducing the chance of loosening under vibration or load. As a result, your systems get more reliable power delivery.

What makes Frigate’s lugs suitable for larger wires in my setup?

These lugs handle conductor sizes from 2.5 mm² to 400 mm², ideal for bigger wires in heavy-duty applications. Their design supports stranded or solid copper conductors, ensuring a secure fit without strain. Thus, they work well for high-power equipment like motors or generators.

How do your lugs hold up under high current demands

They manage currents from 50 A to 1200 A, keeping performance steady even at peak loads. Plus, the high-conductivity copper maintains efficiency, minimizing heat buildup during operation. So, you avoid power drops in demanding manufacturing lines. 

Are your lugs a good fit for outdoor or tough environments?

With an IP54 rating, they resist moisture and oxidation in controlled outdoor settings. However, their bare copper or tin-plated options add flexibility for harsher conditions if needed. This means they stay functional where standard lugs might wear out. 

Why invest in long-barrel lugs over shorter alternatives?

Short-barrel lugs may cost less, but they offer weaker holds for larger wires or high-stress uses. In contrast, the longer barrel boosts stability and durability, cutting risks of failure over time. Therefore, you save on repairs and replacements in the long run. 

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LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

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

Other Locations

  • Bhilai
  • Chennai
  • India
  • Germany
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LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

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

Other Locations

  • Bangalore
  • Chennai
  • India
  • Germany
Become a Frigatian
Become a Supplier

GENERAL ENQUIRIES

  • +91 96778 64606
  • manufacture@frigate.ai
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Long-Barrel Copper 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!

Get Latest Price

Get Price Form

Long-Barrel Copper Lugs

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

Get Latest Price

Get Price Form