Robust and Efficient Aluminium Overhead Line Fittings

Fittings are designed for AAC, AAAC, ACSR and ACAR aluminium conductors and, with bi-metallic or tin-plated versions, for copper conductors. Each fitting is specified for a conductor range, so the exact conductor code or diameter should be stated when ordering.

Common standards are IEC 61284 (requirements and tests for overhead line fittings), ANSI C119.4 (electrical connectors), BS 3288, IS 2121 and utility-specific specifications. Designs are tested for mechanical strength, slip, electrical resistance and heat cycling.

Aluminium fittings match the thermal expansion and electrochemical potential of aluminium conductors, preventing galvanic corrosion and loosening. They are light, strong enough for line loads and resist atmospheric corrosion without additional coatings.

Tension (full-tension) fittings such as dead-end clamps and compression sleeves must hold at least 90–95% of the conductor's rated tensile strength. Non-tension fittings such as PG clamps and tap connectors carry current but not the line tension, so they are tested mainly for electrical performance and slip.

Heat-cycle tests (for example to ANSI C119.4 or IEC 61284) repeatedly heat and cool the connector with current while monitoring resistance and temperature. A stable resistance through the cycles demonstrates that the connection will stay tight in service.

Bolts, nuts and U-bolts are typically hot-dip galvanized steel to ISO 1461 or stainless steel, often with spring or Belleville washers to maintain contact pressure. Split pins and locking devices are supplied where specified.

Yes. Aluminium conductors must be wire-brushed and coated with an oxide-inhibiting compound before installation. Many connectors, such as PG clamps and wedge connectors, can be supplied pre-greased with compound.

Hotline clamps allow a tap or jumper to be connected to an energized line using a hot stick, while wedge tap connectors create a high-pressure, low-resistance tap using a spring-loaded C-body and wedge. Both are widely used in distribution networks.

Yes. Aluminium fittings resist atmospheric corrosion well. For coastal or industrial areas we recommend stainless steel hardware, sealed connectors with inhibitor compound and, where needed, protective covers to limit contamination.

Fittings are cast or stamped with the manufacturer's identification, conductor range, catalogue number and batch code as required by utilities, providing traceability from the field back to production records.

Yes. We produce fittings to utility and EPC contractor drawings, including pattern and die development, prototypes for type testing and production to approved samples.

We can supply material certificates, dimensional inspection reports, galvanizing thickness reports, type-test or routine test reports and packing lists, along with third-party inspection support where required by the utility.

MOQ is 10 pieces for existing designs. Samples are usually available within 2–3 weeks and production orders within 4–6 weeks, depending on quantity, hardware and testing requirements.

Please share the fitting type, conductor type and size range, drawing or utility specification, hardware requirements, test requirements, marking and annual or project quantity.