Aluminum Hot Line Clamps (for USA)

Live-Line / Hot Tap Clamps for Overhead Distribution

Manufactured by BPI

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PRICE: US$ 2.90/each

Overview

We manufacture Aluminum Hot Line Clamps—also referred to as Hotline Clamps, Live-Line Clamps, or Hot Tap Clamps—for overhead electrical distribution systems used across the United States. We are a leading manufacturer of hotline clamps, casting foundry offering hotline clamps, Aluminum Hotline Clamps, bronze Hotline clamps from India.

These clamps are designed to create secure electrical and mechanical connections on energized conductors, allowing utilities to perform tapping, maintenance, and emergency restoration without interrupting power supply.

Built for USA utility supply chains, our clamps combine high-conductivity Aluminum alloy bodies, hot-stick-friendly operating hardware, and export-grade quality control.

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Common Names Used in the USA

• Aluminum Hot Line Clamp

• Hotline Clamp

• Live-Line Clamp

• Hot Tap Clamp

• Distribution Line Tap Clamp

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What Is an Aluminum Hot Line Clamp?

An Aluminum hot line clamp is a connector used to temporarily or semi-permanently tap or connect overhead conductors while the line remains energized.

It is operated using live-line tools (hot sticks) and is widely used by electric utilities to:

• Avoid service interruptions

• Perform maintenance safely on live lines

• Install temporary or emergency connections

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Typical Applications

Utility Distribution

• Live-line tap connections

• Temporary bypasses during maintenance

• Switching and sectionalizing operations

• Emergency restoration work

Substation & Renewable Systems

• Temporary connections during upgrades

• Wind and solar collector circuits

• Field service work where downtime is critical

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Design Features

High Conductivity

• Aluminum alloy body for efficient current transfer

• Outdoor-service surface finish

• Stable electrical contact under load

Live-Line Friendly Operation

• Eye / bail design compatible with hot sticks

• Smooth operating surfaces

• Consistent thread quality for controlled tightening

Mechanical Stability

• Secure clamping action

• Resistance to loosening under vibration

• Designed for overhead service conditions

OEM Customization

• Private labeling and part marking

• Customer-specific part numbers

• Distributor and utility packaging options

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Materials & Construction

Body of Aluminum Hotline Clamps

• High-conductivity Aluminum alloy

• Cast or forged depending on model design

Operating Hardware (as per customer specification)

• Bronze

• Stainless steel

• Galvanized steel

Finish of Aluminum Hotline Clamps

• Natural aluminum

• Corrosion-resistant hardware finishes

• Hot-dip galvanizing (where applicable)

Final material combinations are confirmed per model and utility specification.

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Models & Size Ranges

We manufacture multiple Aluminum hot line clamp configurations commonly used in USA distribution systems.

Common Model Families of Aluminum Hotline Clamps

• Universal hot line clamps (wide conductor range)

• Eye-type hot line clamps for hot-stick operation

• Tap-style and parallel-groove variants (application-specific)

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Technical Torque & Conductor-Range Table (Typical – USA Practice)

Note: Final torque values depend on bolt diameter, material, coating, and utility specification.
Values below are industry-typical guidance only and must be verified against approved drawings.

*Torque values shown are representative and must be confirmed for each utility or distributor program.

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Conductor Compatibility

• AAC

• AAAC

• ACSR

• Aluminum-covered conductors

To select the correct clamp, please provide:

• Conductor type

• AWG / kcmil size

• Run and tap sizes (if applicable)

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Quality Control & Export Supply

Process Controls

• Incoming material verification

• Batch and heat traceability

• CNC machining and dimensional inspection

• Thread gauging and fit checks

• Final inspection before packing

Testing (On Request)

• Dimensional verification to approved drawings

• Mechanical checks

• Corrosion screening for coated hardware

• Lot inspection reports

• PPAP-style documentation (program-based)

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Aluminum vs Bronze Hot Line Clamps (For USA)

Utilities often ask when to use Aluminum versus Bronze hot line clamps. The choice depends on conductor material, duty cycle, and long-term installation intent.

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Material Comparison Table

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When to Choose Aluminum Hot Line Clamps

• Temporary or emergency connections

• Maintenance operations

• Aluminum-to-aluminum conductor interfaces

• Cost-sensitive utility programs

• Situations requiring lightweight handling

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When to Choose Bronze Hot Line Clamps

• Permanent installations

• Substations and high-reliability circuits

• Mixed-metal conductor systems

• High corrosion or coastal environments

• Applications requiring maximum mechanical strength

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Why Utilities Use Both

Many USA utilities specify both Aluminum and Bronze hot line clamps depending on:

• Location (overhead line vs substation)

• Duration of installation

• Environmental severity

• Long-term reliability requirements

We support  both material options, with model-by-model guidance to ensure correct selection.

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Safety Note

Hot line clamps are intended for use by trained personnel using approved live-line procedures and tools. Installation must follow applicable utility safety standards and torque guidelines.

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RFQ / Datasheet Request

To receive a quotation or datasheet, please share:

• Conductor type and size (AWG / kcmil)

• Run and tap size

• Target cross-reference part number (if any)

• Trial and annual quantities

• Packaging / labeling requirements

• Delivery destination and Incoterms

 

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FAQ

Q: Are these clamps used on energized lines?
Yes. Aluminum hot line clamps are designed for live-line work when installed using approved tools and procedures.

Q: Can you match USA distributor part numbers?
Yes. We support cross-reference matching and sample approvals.

Q: Do you offer private labeling?
Yes. Marking, labeling, and custom packaging are available.