Hotline Clamps

HOTLINE CLAMPS

Advanced Engineering for Safe Live-Line Operations

Introduction

Hotline clamps, Bronze Hotline clamps , Aluminum Hotline clamps AKA liveline clamps are essential tools in the electrical utility industry, enabling technicians to perform maintenance and repairs on energized power lines without service interruption. Our range of hotline clamps combines cutting-edge materials science with precision engineering to deliver unparalleled safety, durability, and performance. We BNL India are aleading manufacturers exporters and suppliers of HOTLINE CLAMPS from our casting foundry in Jamnagar india.

Hotline Clamps Specs-

Voltage Ratings

• Low Voltage: 1kV – 33kV
• Medium Voltage: 34kV – 230kV
• High Voltage: 231kV – 800kV

Material Construction

• Body: High-strength aluminum alloy (6061-T6 or 7075-T6) or Aluminium Bronze Alloy (CDA 955, 836 Bronze)
• Insulation: Fiberglass-reinforced plastic (FRP) with UV inhibitors
• Jaw Liners: Replaceable Bronze or Copper alloy
• Hardware: Stainless steel (Grade 316 for superior corrosion resistance)

Mechanical Properties of Hotline clamps

• Tensile Strength: Up to 100,000 psi (depending on model)
• Clamping Force: 1,000 – 5,000 lbs (adjustable)
• Weight: 2 – 15 lbs (varies by model)

Electrical Properties of Hotline clamps

• Dielectric Strength: >100 kV/in
• Insulation Resistance: >50,000 MΩ at 1000V DC
• Current Rating: Up to 2000A continuous (model dependent)

Design Features of Hotline clamps Liveline clamps

Jaw Design

Our Bronze hotline clamps and Aluminum  hotline clamps feature a patented self-aligning jaw mechanism that ensures optimal contact with conductors ranging from 0.1″ to 2.5″ in diameter. The serrated jaw liners provide superior grip while minimizing conductor damage.

Insulation of hotline clamps Liveline clamps

The FRP insulation is manufactured using a pultrusion process, ensuring consistent dielectric properties throughout the material. A proprietary UV-resistant coating extends the service life in harsh outdoor environments.

Ergonomics of hotline clamps

Designed for one-handed operation, our hotline clamps feature:

• Contoured grips with non-slip texture
• Spring-loaded opening mechanism
• Color-coded size indicators

Performance Standards of Bronze Hotline clamps

Our hotline clamps meet or exceed the following industry standards:

• IEEE 935 – Guide on Terminology for Tools and Equipment to Be Used in Live Line Working
• OSHA 1910.269 – Electric Power Generation, Transmission, and Distribution
• ASTM F711 – Standard Specification for Fiberglass-Reinforced Plastic (FRP) Rod and Tube Used in Live Line Tools

Testing and Quality Assurance

Every hotline clamp undergoes rigorous testing, including:

• Dielectric testing at 100kV per foot for 1 minute
• Load testing at 150% of rated capacity
• Accelerated weathering tests (1000 hours of UV and moisture exposure)

Maintenance and Care of Hotline Clamps

To ensure long-term reliability:

• Clean with silicone-free solvent after each use
• Inspect for signs of wear or damage before each use
• Re-test dielectric properties annually or after 1000 hours of use
• Replace jaw liners every 500 operations or when wear is visible

Custom Solutions-Hotline Clamps or Liveline clamps

Our manufacturing and engineering team can develop custom hotline clamp solutions for unique applications. Contact our technical support department to discuss your specific requirements.

Ordering Information for manufactured Hotline Clamps

Hotline clamps are available in the following configurations:

• Model HC-100: Low Voltage Series (1kV – 33kV)
• Model HC-200: Medium Voltage Series (34kV – 230kV)
• Model HC-300: High Voltage Series (231kV – 800kV)

Each series offers multiple size options to accommodate various conductor diameters.

Contact Us (Manufacturers of Hotline clamps)

For technical support or understanding on Hotline Clamps, custom orders, or to request a quote:

Related terms-

• Live-line clamps
• Hot stick clamps
• Conductor clamps
• Energized line tools
• Overhead line clamps
• Transmission line clamps
• Distribution line clamps
• Utility pole clamps
• Power line maintenance tools
• Electrical hotline tools
• High-voltage clamps
• Insulated line clamps
• Temporary jumper clamps
• Bare hand clamps
• Shotgun stick clamps
• Pole top clamps
• Overhead conductor tools
• Live wire maintenance equipment
• Electrical utility clamps
• Lineman clamps
• Hot line maintenance gear
• Electrical grid repair tools
• Substation maintenance clamps
• Powerline repair equipment
• Insulated hotline tools