Hotline Clamps, Bronze Hotline Clamps

BRONZE HOT LINE CLAMPS – TECHNICAL PRODUCT PAGE

Bronze Hot Line Clamps are precision-engineered connectors used for installing, removing, or repositioning energized overhead conductors and tap connections on distribution lines. Designed for hot-stick/live-line work, these clamps ensure a safe, mechanically strong, low-resistance connection suitable for utility networks, OEM equipment builders, and contractors.

Conex manufactures high-strength Bronze Hot Line Clamps with stainless-steel forged eyebolts, protected threads, optimized current paths, and weather-resistant Bronze alloys for long service life in demanding outdoor conditions.

Price: US$ 13.40/Kilogram 

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KEY FEATURES & BENEFITS

• High-strength Bronze alloy body (cast or forged)

• Protected thread design keeps heat and current away from screw threads

• Forged stainless-steel eyebolt for smooth hot-stick operation

• Precision-machined serrated jaws for excellent conductor grip

• Wide conductor compatibility: Copper, Aluminum, ACSR (#6 AWG to 477 kcmil)

• Designed for energized working (5–38 kV distribution lines)

• Low electrical contact resistance for stable performance

• Engineered for long-term outdoor exposure: UV, salt-air, industrial pollution

• Optional plated or silvered contact areas where required

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TYPICAL APPLICATIONS

• Overhead distribution feeder taps

• Temporary jumper/bypass connections

• Switching, sectionalizing, reconductoring work

• Connections to fuses, reclosers, switches & riser poles

• Substation maintenance tap points

• Fault restoration by utility linemen

• Renewable energy collector lines

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DESIGN & CONSTRUCTION

• Clamp Body: Cast/forged Bronze with high mechanical strength

• Eyebolt: Forged stainless steel (304 or 316); smooth eye for hot-stick

• Jaw: Serrated/grooved to match Cu/Al/ACSR conductor

• Threads: Protected from current path to prevent galling and overheating

• Hardware: Silicon Bronze or SS nuts, washers and springs

• Finish: Natural Bronze, Tin-plated, Nickel-plated, or Silvered

• Passivation: Benzotriazole-based anti-tarnish coating available

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MATERIAL GRADES AVAILABLE

Cast Tin Bronze:

• UNS C83600 (ASTM B62), EN CC491K, JIS BC3, Chinese QSn5Zn5Pb2

• General-purpose clamp bodies; good castability

High-Strength Manganese Bronze:

• UNS C86500 / C86700, EN CuZn40Mn2Fe1

• Very high tensile strength and wear resistance

Aluminum Bronze:

• UNS C95400 (ASTM B148), EN CC333G

• Excellent corrosion resistance in coastal/industrial atmospheres

Silicon Bronze (Wrought):

• UNS C65500 (ASTM B98), EN CW116C

• High strength for bolts, eyebolts, hardware components

Silicon Bronze (Cast):

• UNS C87300 / C87500

• Good corrosion resistance and mechanical properties

Stainless Steel Eyebolts:

• AISI 304 / 316 (S30400 / S31600)

• For maximum corrosion protection and hot-stick working

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MANUFACTURING PROCESSES

• Tooling design with CAD/CAM and flow simulation

• Gravity die casting / shell mold casting

• Closed-die forging for eyebolts or heavy-duty bodies

• CNC machining of jaws, threads, hinge pins and contact faces

• Shot-blasting and vibratory finishing

• Silver/Tin/Nickel plating as required

• Lubrication with high-temperature grease (optional)

• Mechanical pull testing, thermal cycling & electrical resistance testing

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TYPICAL DIMENSIONAL RANGE (REPRESENTATIVE CHART)

Custom designs and OEM-equivalent geometries can be produced.

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PERFORMANCE & TESTING

• Current rating: 200–600 A (continuous, size dependent)

• Fault withstand: Tested to utility-specified short-circuit levels

• Millivolt drop: Ultra-low contact resistance

• Mechanical testing: Tensile and bending loads

• Thermal cycling: Repeated heating cycles to mimic load variation

• Environmental testing: Salt-spray, humidity, accelerated corrosion tests

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STANDARDS & COMPLIANCE

• Meets/exceeds ANSI C119.4 mechanical and electrical connector requirements

• RoHS material compliance

• Complete PPAP, MTC, Dimensional Reports available

• Full batch traceability

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SURFACE FINISH OPTIONS

• Natural Bronze (shot blasted / passivated)

• Tin-plated (recommended for aluminum conductors)

• Nickel-plated (corrosion protection)

• Silver plating (high-current specialty applications)

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INDUSTRIES USING BRONZE HOT LINE CLAMPS

• Transmission & Distribution Utilities

• Municipal & Cooperative Utilities

• Switchgear & Recloser OEMs

• Renewable Energy (Wind/Solar collector lines)

• Industrial overhead networks

• Rail & metro overhead power (where applicable)

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TURNAROUND TIME

4–6 weeks standard lead time
Faster delivery possible based on stock, tooling and quantity.

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WHY CHOOSE OUR BRONZE HOT LINE CLAMPS?

• Deep E-E-A-T technical expertise in Bronze, Copper, and Stainless Steel metallurgy

• Ability to match Hubbell, CMC, Burndy or other OEM clamp types

• Reliable communication for USA customers (fast, precise, technical)

• World-class casting, forging, and CNC machining capability

• Strict quality assurance with full documentation

• Competitive pricing and global shipping efficiency

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FREQUENTLY ASKED QUESTIONS (FAQ)

(15 questions, keyword-optimized; max 4 lines each)

1. What are Bronze Hot Line Clamps used for?
   They create temporary or semi-permanent connections on energized overhead lines during hot-stick work, maintenance, or switching operations.

2. Can these clamps work with both copper and aluminum conductors?
   Yes. Serrated jaws and optional tin-plated surfaces ensure compatibility with Cu, Al, and ACSR conductors.

3. What voltage range are these clamps suitable for?
   Typically used on 5–38 kV distribution networks; suitability depends on utility practices.

4. Do the clamps have protected threads?
   Yes—the current path bypasses the threads, preventing overheating and extending mechanical life.

5. Are your eyebolts forged?
   Yes, stainless-steel forged eyebolts ensure strength, smooth operation and long service life.

6. Do you match Hubbell or CMC clamp models?
   We can produce compatible designs after reviewing samples or drawings.

7. Are these suitable for permanent connections?
   Generally used for energized temporary taps; permanent installations prefer compression or bolted lugs.

8. Do you supply high-temperature grease on threads?
   Upon request, clamps can be supplied lubricated for smooth live-line tool operation.

9. Can I request custom markings or OEM branding?
   Yes. Your logo, part numbers, and batch codes can be cast or stamped.

10. Do you offer PPAP or UL-style documentation?
    Yes, full PPAP, dimensional reports, and inspection records are available.

11. What testing do you perform?
    Mechanical, thermal, electrical resistance, corrosion tests and visual/functional inspection.

12. Are 3D CAD drawings available?
    We provide full drawings and 3D models for engineering approval.

13. How are clamps packaged?
    Individually wrapped in corrosion-inhibiting bags, boxed and palletized for export.

14. What information do you need for quotation?
    Conductor range, drawings/samples, finish required, annual quantities and test specifications.

15. What is the minimum order quantity?
    MOQ depends on clamp size and tooling, but we support small engineering development orders.

    USA Sales: We are a trusted global supplier of precision metal parts for the electrical industry, proudly partnering with leading USA companies to power innovation and infrastructure. From Fortune 500 manufacturers to innovative tech giants, our high-quality components meet rigorous U.S. standards for performance, durability, and safety. By combining advanced manufacturing with reliable delivery and dedicated stateside support, we help American businesses streamline supply chains, reduce costs, and drive the future of electrical systems, renewable energy, and smart grid technology. Choose a supplier engineered for the demands of the U.S. market. We can also offer DDP pricing within USA to every possible state.