High-Conductivity Aluminium Lugs and Cable Terminals for Electrical Systems
Our aluminium lugs and cable terminals ensure high conductivity and secure connections. Designed for electrical systems, they provide reliability, ease of installation, and durability.
Ensuring safe and efficient electrical connections with high-conductivity aluminium lugs and cable terminals for modern power systems.
At Conex Aluminium Components, our aluminium lugs and cable terminals are engineered to provide excellent electrical conductivity, mechanical strength, and corrosion resistance. These components are used for terminating and joining electrical cables, making them essential for power distribution systems. Our lugs and terminals are available in various configurations to meet specific electrical requirements, ensuring safe and reliable connections. We maintain strict quality control measures to ensure the highest standards of performance and safety.
We manufacture one-hole and two-hole compression lugs, long-barrel lugs, transformer lugs with four or more holes, mechanical/bolted lugs, bi-metallic Al–Cu lugs and custom terminals for aluminium conductors.
Compression lugs are produced from high-purity, high-conductivity aluminium (EC grade/1350 or 1060, typically above 99.5% Al) so the lug can be crimped without cracking and has conductivity close to the conductor.
Lugs are designed and tested to IEC 61238-1, DIN 46329, UL 486A-486B, BS 4579 and utility specifications as required.
Select by conductor cross-section and class (round, compacted, sector), stud or bolt size, number of holes and palm dimensions. The lug barrel is marked with size and die code.
Aluminium lugs are pre-filled with oxide-inhibiting compound to break down the oxide layer during crimping and seal the joint from moisture, maintaining low contact resistance.
Aluminium lugs should be tin plated or bi-metallic (Al–Cu) when connecting to copper busbars to prevent galvanic corrosion.
Long-barrel lugs have extra length for two or more crimps, providing higher pull-out strength and lower resistance, which is required for medium-voltage and high-current applications.
The number of crimps depends on lug size and design and is marked on the lug or specified in the catalogue. Larger sizes typically need two to four crimps.
Hexagonal or deep-indent crimping dies on hydraulic tools are used. The die must match the lug size and code to achieve the correct compression.
Yes. Sealed barrels and tin plating protect aluminium lugs outdoors, and heat-shrink sleeves can be added for extra protection.
Yes. We produce lugs with special palm shapes, hole sizes and barrel dimensions to customer drawings.
Testing includes dimensional checks, hardness, plating thickness, crimp pull-out tests and electrical resistance/heat-cycle tests as required.
Plain aluminium or tin plated finishes are available depending on the application.
MOQ is 10 pieces. Samples are available in 2–3 weeks and production in 4–6 weeks.
Please provide conductor size and type, number of holes, hole size and spacing, plating requirement, standard and quantity.
Need Aluminium Lugs - Cable Terminals? Get a Fast, Detailed Quotation
Send your drawing (STEP, IGES, DWG, DXF or PDF) with material grade, finish and quantity. Our engineers reply with a DFM review, price and lead time. MOQ 10 pcs • ISO 9001:2015 • Exports to USA, UK, Europe, Canada & Australia.
