Hotline Clamps (Bronze Hotline Clamps)
Price: US$ 4.40/each, CIF US Sea port
High-Conductivity, Live-Line Hardware for Power Transmission & Distribution
We are one of the leading manufacturers and exporters of Hotline Clamps from India . We have been supplying Bronze Hotline Clamps, Aluminum Hotline clamps, and live-line power hardware to the world market for many decades. Our Hotline Clamps are engineered for live-line (hot-line) maintenance, enabling utilities and EPC contractors to work safely on energized conductors without service interruption. Designed for reliability in harsh outdoor environments, our Bronze Hotline Clamps deliver consistent conductivity, mechanical strength, corrosion resistance, and repeatable performance—attributes demanded by utilities across USA, Canada, UK, Australia, Middle East, and Europe. With three decades of export experience, a strong engineering backbone, and flexible manufacturing, we support both standard utility designs and customer-specific drawings, ensuring compliance with international standards while meeting fast project timelines. Our focus on E-E-A-T—Experience, Expertise, Authoritativeness, and Trust—shows in our material traceability, process control, inspection discipline, and transparent communication with customers.
Technical Overview
Hotline Clamps—also known as Hot Line Clamps, Live Line Clamps, Hot Stick Clamps, Utility Hotline Hardware, or Energized Line Clamps—are temporary or semi-permanent connectors used during maintenance, bypassing, grounding, or current transfer on overhead transmission and distribution lines. Our Bronze Hotline Clamps are preferred where low contact resistance, high spring force, and excellent corrosion resistance are critical. Typical applications include jumpering, bypassing damaged conductors, load transfer, temporary taps, and live-line work using insulated hot sticks. The clamp jaws, springs, and contact geometry are optimized to maintain stable pressure on ACSR, AAAC, AAC, Copper, and Aluminium conductors, even under vibration and thermal cycling.
Material Grades & Global Equivalents
| Material Family | Common Grades | USA / ASTM | Europe / EN / BS | Japan / JIS | China / GB |
|---|---|---|---|---|---|
| Bronze (High-Conductivity) | Silicon Bronze, Phosphor Bronze | ASTM B584 C87500, C87600; ASTM B505 | EN 1982 CC761S | JIS CAC502 | GB ZCuSi3 |
| Copper Alloys | ETP / DHP | ASTM B152 C11000 / C12200 | EN CW004A / CW024A | JIS C1100 | GB T2 |
| Brass (Selective Use) | Low-Lead / DZR | ASTM B455 | EN CW602N | JIS C3531 | GB Hpb59 |
| Stainless Steel (Springs/Fasteners) | Austenitic | ASTM A276 304/316 | EN 1.4301 / 1.4401 | JIS SUS304/316 | GB 06Cr19Ni10 |
| Aluminium (Optional Parts) | High-Strength | ASTM B221 6061-T6 | EN AW-6061 | JIS A6061 | GB 6061 |
Material selection is guided by conductivity, galvanic compatibility, mechanical strength, and service environment.
Manufacturing Processes & Machinery Used
Our Hotline Clamps are produced using controlled casting and precision machining. Bronze components are manufactured via gravity die casting or shell molding for dense microstructure, followed by CNC machining to achieve accurate jaw profiles and repeatable contact geometry. Springs are cold-formed and heat-treated from Stainless Steel. Typical machinery includes CNC VMCs, horizontal machining centers, power presses, induction furnaces, shot blasting units, and calibrated inspection instruments. Each batch undergoes process inspection, dimensional checks, material verification, and final functional checks.
Typical Parts Produced
Bronze Hotline clamp body (fixed/movable jaw), serrated contact inserts, spring assemblies, operating eye/hook for hot stick engagement, Stainless Steel pins/fasteners, and optional Copper/Bronze shunts for current carrying bypass. We also offer Aluminum Hotline clamps in high volumes.
Hotline Clamps- Sizes and Dimensions
| Catalog Code | Conductor | Tap Conductor |
Run Dia (in) |
Run Max | Run Min | Tap Dia (in) | Tap Max | Tap Min | Length (in) | Height (in) | Width (in) | Tap Nut (in) |
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| CX-HLC-1520-CU | CU | CU | .128 – .414 | 2/0 STR | #8 SOL | .128 – .414 | 2/0 STR | #8 SOL | 4.5 | 1.25 | 2.75 | 9/16 |
| CX-HLC-1520-AL | AL | AL/CU | .128 – .414 | 2/0 STR | #8 SOL | .128 – .414 | 2/0 STR | #8 SOL | 4.5 | 1.25 | 2.75 | 9/16 |
| CX-HLC-1530-CU | CU | CU | .162 – .745 | 400 MCM | #6 SOL | .152 – .682 | 4/0 STR | #6 SOL | 6.5 | 1.75 | 2.50 | 3/4 |
| CX-HLC-1530-AL | AL | AL/CU | .162 – .745 | 336.4 MCM ACSR | #6 SOL | .152 – .682 | 4/0 STR | #6 SOL | 6.5 | 1.75 | 2.50 | 3/4 |
*Current rating depends on conductor type, duty cycle, and ambient conditions.
Plating / Surface Finish
Natural Bronze finish, optional Tin plating, Silver flash on contact areas (on request), and passivation for enhanced corrosion resistance in coastal or polluted environments.
Industries & Applications
Electric utilities, transmission & distribution companies, EPC contractors, live-line maintenance teams, rail electrification, renewable energy interconnections, substations, and emergency restoration crews.
Tolerances & Quality for Hotline clamps of Bronze and Aluminum
Typical machining tolerance ±0.05 mm on critical interfaces. Springs tested for repeatable force. Inspection follows ISO 9001:2015 systems with calibrated gauges. Material test certificates available.
Turnaround Time for Hotline Clamps
4–6 weeks for standard sizes; expedited production available for urgent utility shutdown windows.
Performance Metrics (Typical)
Low contact resistance, stable spring force over thermal cycles, corrosion resistance in outdoor exposure, and consistent current transfer during live-line operations.
Why Choose Our Bronze Hotline Clamps
Customers choose us for faster turnaround, engineering support, and clear communication. Our team routinely suggests drawing optimizations, alloy upgrades, or finish improvements to extend service life. With three decades of global exposure, flexible batch sizes, custom labeling/packaging, and responsive after-sales support, we deliver dependable solutions—not just parts.
Packaging & Shipping
Individually wrapped, moisture-protected export cartons, palletized as required. Custom labels, barcodes, and customer logos supported. Shipped worldwide by sea or air with complete documentation.
Customer Testimonials
Michael R., Utility Buyer (USA): “The Bronze Hotline Clamps arrived on time and exceeded our conductivity expectations. Excellent communication and drawings support.”
James T., EPC Manager (Australia): “Consistent quality and quick turnaround helped us complete live-line work without delays. Highly reliable supplier.”
Typical Q & A (Embedded Keywords)
-
What are Hotline Clamps used for? Live-line maintenance, bypassing, and temporary connections on energized conductors.
-
Why Bronze for Hotline Clamps? Bronze offers high conductivity with superior corrosion resistance outdoors.
-
Are your clamps suitable for ACSR and AAAC? Yes, designs support ACSR, AAAC, AAC, Copper, and Aluminium.
-
Do you meet ASTM standards? Materials and processes align with ASTM and equivalent international standards.
-
Can you customize dimensions? Yes, we manufacture as per customer drawings or utility specs.
-
What is the typical current rating? Ratings vary by size; designs support 200–600 A typical.
-
Do you offer plating? Tin or Silver flash available on request.
-
What is the lead time? Standard 4–6 weeks.
-
Do you provide test certificates? Material and inspection reports are available.
-
Are clamps compatible with hot sticks? Yes, operating eyes are designed for hot stick use.
-
What environments are suitable? Inland, coastal, and polluted atmospheres with proper finish.
-
Minimum order quantity? Flexible MOQs for export customers.
-
Can you brand packaging? Custom labels and logos supported.
-
Do you ship to USA utilities? Yes, regular exports to North America.
-
Can engineering suggest improvements? Our team actively reviews and optimizes designs.
Glossary of Terms
Hotline Clamp: Connector for energized line work.
Live-Line Maintenance: Working on power lines without de-energizing.
Contact Resistance: Electrical resistance at mating surfaces.
ACSR: Aluminium Conductor Steel Reinforced.
AAAC/AAC: All Aluminium Alloy/Conductor.
Related Terms
Hot Line Clamp, Live Line Clamp, Bronze Utility Clamp, Hot Stick Clamp, Overhead Line Hardware, Temporary Bypass Clamp, Utility Maintenance Clamp.
Call-to-Action:
Request a quick quote, email us for a technical brochure, or contact us via phone/WhatsApp to discuss your live-line application and drawings.
