Copper Lugs Manufacturer in India
Yeshwant Wires is one of the leading Copper Lug manufacturers in India, delivering premium-quality copper and tinned Copper Lugs designed for superior performance in power distribution, switchgear panels, transformers, motors, and industrial electrical systems. Our Copper Lugs ensure safe, reliable electrical connections, minimal resistance, and exceptional durability, providing unmatched performance for mission-critical power applications.
Engineered with 99.99% electrolytic grade copper, precision manufacturing, and corrosion-resistant finishes, these Copper Lugs offer excellent electrical conductivity, mechanical strength, and long service life in demanding environments. Each lug is tested to meet or exceed IS 1885, IEC 61238-1, ASTM B170, and BS 4579 international standards. Available in crimping, bolt-on, compression, and custom designs, our Copper Lugs are ideal for both industrial power systems and commercial electrical installations.
What are Copper Lugs?
Copper Lugs are electrical connectors used to securely attach cables to electrical equipment, providing safe, low-resistance connections for power transmission and distribution. They feature a barrel for cable insertion and a palm or hole for bolting to equipment terminals, making them essential components in switchgear, transformers, battery systems, and motor connections.
Manufactured from high-purity copper, Copper Lugs offer superior conductivity compared to alternative connection methods. They are widely used in industrial automation, power generation, renewable energy systems, automotive applications, and heavy machinery where reliable electrical connections are critical for safety and performance.
Key Features & Technical Advantages
- Superior Conductivity: 99.99% pure copper ensures minimal energy loss and maximum current flow.
- Exceptional Durability: Withstands mechanical stress, vibration, and high electrical loads.
- Corrosion Protection: Available in bare and tinned finishes for extended operational life.
- Multiple Configurations: Crimping, bolt-on, compression, and pin-type lugs for diverse applications.
- Precision Manufacturing: Tight dimensional tolerances ensure perfect fit and optimal performance.
- Wide Size Range: Compatible with cables from 1.5 mm² to 1000 mm² and beyond.
- Temperature Resistant: Reliable operation from -40°C to +150°C in harsh environments.
- Easy Installation: Designed for efficient crimping or bolting with standard tools.
- Standards Compliant: Meets IS, IEC, ASTM, and BS international quality standards.
Comprehensive Technical Specifications
| Property | Specification | Significance |
|---|---|---|
| Material | High-Conductivity Electrolytic Copper (99.9% Cu), often Tin-Plated (Electro-tinning). | Copper ensures minimal resistance and heat generation. Tin plating prevents oxidation/corrosion, especially in humid or outdoor conditions, ensuring the long-term integrity of the electrical joint. |
| Barrel Type/Wall | Standard/Heavy Duty (Thick Wall), Seamless Tubular or Brazed Seam. | A seamless barrel provides superior integrity and concentricity for crimping. Heavy-duty (thick wall) lugs are used for higher vibration environments or when a larger surface area is needed for welding/brazing. |
| Cable Termination Type | Standard Compression (Crimp), Solder, or Mechanical (Set-screw). | Compression lugs are the most common, requiring a specific tool to deform the barrel onto the conductor. Solder lugs are used for maximum reliability and low resistance, while mechanical lugs allow for easy field installation without specialized tools. |
| Conductor Size Compatibility | Specified by Metric CSA (e.g., 16 mm² to 300 mm²) or AWG/kcmil (e.g., #8 AWG to 750 kcmil). | The barrel size must precisely match the cable's cross-sectional area to achieve a gas-tight, low-resistance, and mechanically strong crimp joint. |
| Stud/Bolt Hole Size | Specified by Nominal Diameter (e.g., M8, M10, 3/8", 1/2"). | The terminal pad hole must match the diameter of the connecting bolt/stud (e.g., on a busbar, breaker, or battery post) to ensure a secure and flush electrical contact. |
| Current Rating (Ampacity) | Matched to the maximum rating of the smallest connected conductor (e.g., the cable). | A properly crimped lug should be considered part of the conductor; its resistance must be negligible and its temperature rise must be below acceptable limits under rated load. |
| Key Function | Secure Transition from a flexible, stranded conductor to a rigid, bolted terminal point. | Lugs provide a large, flat, rigid surface area (the palm/pad) necessary for creating a low-resistance, high-pressure bolted electrical connection. |
| Relevant Standards | UL 486A-486B (Safety), RoHS/REACH (Environmental), and often manufacturer-specific type testing to relevant equipment standards. | Compliance ensures the lug is rated to prevent strand pullout and maintain a low-resistance connection under fault current conditions. |
| Copper Tubular Lug — Typical Dimensions (mm) | |||||
|---|---|---|---|---|---|
| Cable Size (mm²) | Stud Hole ⌀ (mm) | Barrel ⌀ (mm) | Barrel Length (mm) | Overall Length (mm) | Tongue Width (mm) |
| 1.5 | 4.2 | 3.8 | 12 | 25 | 8 |
| 2.5 | 4.2 | 4.2 | 13 | 27 | 9 |
| 4 | 5.3 | 4.8 | 15 | 30 | 10 |
| 6 | 5.3 | 5.5 | 16 | 33 | 12 |
| 10 | 6.4 | 7.0 | 18 | 36 | 14 |
| 16 | 6.4 | 8.4 | 20 | 40 | 16 |
| 25 | 8.4 | 10.2 | 22 | 46 | 18 |
| 35 | 8.4 | 11.7 | 24 | 50 | 20 |
| 50 | 10.5 | 13.8 | 26 | 55 | 22 |
| 70 | 10.5 | 16.0 | 28 | 60 | 25 |
| 95 | 12.5 | 18.4 | 32 | 68 | 28 |
| 120 | 12.5 | 20.7 | 36 | 75 | 30 |
| 150 | 12.5 | 23.0 | 40 | 82 | 33 |
| 185 | 16.5 | 25.8 | 42 | 88 | 36 |
| 240 | 16.5 | 29.0 | 45 | 95 | 40 |
| 300 | 20.5 | 32.5 | 50 | 105 | 44 |
| 400 | 20.5 | 36.5 | 55 | 115 | 48 |
Types of Copper Lugs We Manufacture
Crimping Copper Lugs
Permanent connections using hydraulic or mechanical crimping tools. Ideal for high-current applications in power distribution and industrial machinery.
Bolt-On Copper Lugs
Set screw design for easy installation and maintenance. Perfect for transformer connections, switchgear panels, and temporary installations.
Compression Copper Lugs
High-strength connections using compression dies. Excellent for underground cables, substations, and heavy-duty electrical systems.
Battery Copper Lugs
Specialized lugs for battery terminals in automotive, UPS systems, solar installations, and marine applications.
Applications & Industries
Power Distribution
Substations, transformers, switchgear panels
Renewable Energy
Solar panels, wind turbines, battery storage
Automotive
Vehicle batteries, starter motors, alternators
Industrial Machinery
Motors, pumps, control panels, heavy equipment
Marine & Railway
Ship electrical systems, locomotive power
Construction
Building electrical systems, infrastructure
Why Choose Yeshwant Wires?
Trusted Manufacturer
Recognized Copper Lug manufacturer in India with decades of manufacturing excellence and technical expertise.
Custom Solutions
Tailor-made Copper Lugs in special sizes, finishes, and configurations for unique applications.
Premium Materials
Made with 99.99% pure electrolytic copper for maximum conductivity and durability.
Global Standards
Complies with IS, IEC, ASTM, and BS international quality and safety standards.
Competitive Pricing
Factory-direct pricing with bulk order discounts and flexible payment terms.
Pan-India Supply
Efficient logistics network ensuring timely delivery to all industrial regions across India.
