Bronze Bolted Stud Connectors, Bronze Substation Connectors
Bronze Bolted Stud Connectors are heavy-duty mechanical electrical connectors designed for cable-to-stud and cable-to-equipment terminations used throughout substations, transformers, switchgear, and grounding systems. Their bolted design ensures a mechanically strong, electrically efficient joint with very low contact resistance, even under high current, vibration, and outdoor environmental conditions.
These connectors are engineered for compatibility with UNC and UNF threaded studs and bolts, commonly used across North American electrical equipment.
Material Composition
Bronze Bolted Stud Connectors are typically manufactured using:
High-Conductivity Bronze Alloys
C83600 / C83800 (Red Brass)
C84400 (Semi-Red Brass)
C95200 / C95400 (Silicon Bronze)
C95500 (Aluminium Bronze) for high strength
Hardware Options (All UNC/UNF Threads)
Silicon Bronze bolts (preferred for corrosion resistance)
Stainless Steel 304 / 316 UNC/UNF bolts and nuts
Bronze washers or stainless steel washers
Optional tin-plating for enhanced conductivity
These alloys offer optimal mechanical strength, conductivity, and corrosion resistance in substations.
Manufacturing Processes
To achieve high quality and consistency, Bronze Bolted Stud Connectors are produced through:
Precision Sand Casting
Shell Mould Casting for finer details
Gravity Die Casting for high mechanical strength
CNC Machining of all critical areas (bolt pads, stud holes, conductor grooves)
Deburring & Shot Blasting
Optional Tin Plating or Nickel Plating
All machining (stud bores, bolt seats) is aligned for UNC/UNF hardware compatibility.
Design Features
High-performance stud connectors feature:
Broad, machined conductor seats for maximum contact area
UNC/UNF bolt threading for all clamps and hardware
Precisely machined stud holes matching U.S. substation equipment
Uniform clamping pressure due to multi-bolt design
High vibration resistance due to mechanical locking hardware
Self-aligning contact faces to reduce installation error
Thermal stability for continuous load cycling
Electrical & Mechanical Performance
Low contact resistance due to solid bronze body and large surface area
Stable thermal behavior under high load cycling
High pull-out strength due to multi-bolt clamping
Excellent corrosion resistance, even in coastal or polluted environments
High current-carrying capacity suitable for distribution and substation networks
Installation Guidelines (UNC/UNF Hardware)
Clean conductor strands and connector bore
Insert conductor fully into machined groove
Position connector over UNC/UNF stud (e.g., 3/8″-16 UNC, 1/2″-13 UNC, etc.)
Tighten each bolt incrementally in alternating patterns
Use a calibrated torque wrench
Follow recommended torque (example below)
Re-check torque after initial thermal cycles if required
Applications
Bronze Bolted Stud Connectors are ideal for:
Substation terminations (HV/LV)
Transformer cable-to-stud connections
Circuit breaker and switchgear pads
Busbar connections (flat or drilled pads)
Earthing and grounding networks
Retrofit & maintenance jobs requiring reusability
Temporary and emergency cable terminations
Their mechanical bolting method eliminates the need for crimping, welding, or specialized tools.
Dimensional Options (UNC / UNF Example Range)
(Customize to your catalogue. Thread sizes shown are typical in U.S. substation equipment.)
| Model | Conductor Range (AWG/KCMIL) | Stud Thread | No. of Bolts | Bolt Thread | Material |
|---|---|---|---|---|---|
| BNLBSC-2/0 | 2 AWG – 2/0 | 5/16″-18 UNC | 2 | 1/4″-20 UNC | Bronze |
| BNLBSC-4/0 | 1/0 – 4/0 | 3/8″-16 UNC | 2 | 5/16″-18 UNC | Bronze |
| BNLBSC-350 | 4/0 – 350 MCM | 3/8″-16 or 1/2″-13 UNC | 2–3 | 5/16″-18 or 3/8″-16 UNC | Bronze |
| BNLBSC-500 | 350 – 500 MCM | 1/2″-13 UNC | 3–4 | 3/8″-16 UNC | Silicon Bronze |
| BNLBSC-750 | 500 – 750 MCM | 5/8″-11 UNC | 4 | 1/2″-13 UNC | Aluminium Bronze |
All threads are UNC/UNF per ASTM standards.
Custom conductor sizes and stud patterns can be manufactured on request.
Recommended Hardware Torque (Typical Values)
| Bolt Size | Thread Type | Typical Torque (ft-lb) | Notes |
|---|---|---|---|
| 1/4″-20 | UNC | 6–8 ft-lb | Light clamping |
| 5/16″-18 | UNC | 12–18 ft-lb | Medium connectors |
| 3/8″-16 | UNC | 25–30 ft-lb | Substation grade |
| 1/2″-13 | UNC | 45–60 ft-lb | Heavy-duty clamp |
| 5/8″-11 | UNC | 80–100 ft-lb | High current applications |
(Exact torque may vary based on alloy and plating—final values as per your QA.)
Quality Standards & Testing
Each connector undergoes:
Dimensional inspection
Thread gauge check (UNC/UNF)
Mechanical pull-out test
Contact resistance test
Thermal cycling test
Corrosion test (salt spray)
Visual surface and burr inspection
Industries Served
Electrical utilities
Transformer & switchgear OEMs
EPC contractors
Renewable energy substations
Railways, metros & airports
Oil & gas and petrochemical industries
Steel plants & heavy industries
Why Choose Our Bronze Bolted Stud Connectors
Over 30 years of global manufacturing export experience
Precision machining with UNC/UNF-compatible tooling
Consistent quality, high repeatability, large-scale capacity
Tin-plated or bare bronze options
Custom conductor/bolt/stud configurations
Fast turnaround: 4–6 weeks
Excellent customer communication and technical support
Proven reliability in U.S. and European utilities
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