Tubular compression lugs
Copper tube lugs, crimped onto the cable with a compression die.
For power cables into switchgear, transformers and busbars
Custom lugs and terminals, made to your drawing.
Cable lugs and terminals in copper, brass and aluminium, crimped, soldered or bolted. Manufactured in India, plated and inspected against your drawing, and delivered to your Incoterm.
- Copper, brass or bimetallic
- Tin plated
- Measured records
Cable lug, 95 mm², M12, tin platedDWG REV. B
- Material
- Copper tube
- Plating
- Tin, electroplated
- Critical dimension
- Stud hole Ø13.0 +0.2 mm
- Inspection
- Against the drawing
What we make
Two-hole lugs
Two bolt holes at the spacing your drawing names, so the lug cannot turn on its fixing.
For connections that see vibration or torque
Long-barrel lugs
A longer barrel with room for two crimps, for higher pull-out strength.
For heavy-duty and sealed terminations
Bimetallic lugs
An aluminium barrel joined to a copper palm, to land an aluminium cable on a copper terminal.
For aluminium cables on copper busbars
Bolted lugs
Mechanical lugs that clamp the conductor with screws, with no crimp tool needed.
For field terminations and mixed cable sizes
Brass and custom terminals
Soldering lugs, ring, pin, fork and flag terminals in copper or brass, stamped, formed or machined to your drawing.
For small cables, control wiring and earthing
Choosing a lug
Match the barrel to the cable, and the palm to the terminal it lands on.
Barrel for the cable
- Standard barrel
- Sized to the conductor cross-section and class, for one crimp.Watch for: A barrel that does not match the conductor class gives a weak crimp.
- Long barrel
- Room for two crimps, for higher pull-out strength.Watch for: Needs more length at the terminal.
- Bimetallic
- Aluminium barrel for aluminium cable, copper palm for the terminal.Watch for: The joint between the two metals must be sound; ask for the test result.
Palm for the terminal
- One-hole
- The simplest fixing, on a single stud or bolt.Watch for: Can turn on its stud under vibration.
- Two-hole
- Two bolts hold the lug square and stop it turning.Watch for: Hole spacing must match the terminal.
- Angled, 45° or 90°
- Turns the cable to save space in tight panels.Watch for: Give the angle and direction on the drawing.
Material for the current
- Copper
- Highest conductivity, for power cables and high current.Watch for: Soft, so palms and threads need care when tightened.
- Brass
- Stronger than copper and easy to machine and solder, for soldering lugs, small terminals and earth connections.Watch for: About a quarter of the conductivity of copper, so not for high-current power cables.
- Aluminium
- Light, for aluminium cables on aluminium terminals.Watch for: Contact faces need a jointing compound against oxide.
Specifications
- Types
- Tubular compression, two-hole, long-barrel, bimetallic and bolted lugs; soldering lugs; ring, pin, fork and flag terminals
- Materials
- Copper tube (Cu-ETP, Cu-DHP); brass (CW614N, CW617N) for soldering lugs and terminals; aluminium; bimetallic copper and aluminium
- Cable sizes
- 1.5–630 mm² standard; up to 1000 mm² on review
- Stud sizes
- M4–M20 standard
- Plating
- Tin, electroplated; silver or nickel on request
- Standards
- DIN 46235 and DIN 46234 dimensions where your drawing names them
- Checks
- Drawing dimensions, hole position and plating thickness; conductivity where specified
- Quantities
- Prototype builds to mass production
Copper, aluminium or bimetallic
Use a lug of the same metal as the cable. Where aluminium cable lands on copper, use a bimetallic lug.
Why it matters: where copper and aluminium touch and moisture gets in, the aluminium corrodes and the joint heats up. A bimetallic lug moves that junction inside a sealed joint.
Copper to copper
Copper cable on a copper terminal takes a copper lug, usually tin plated.
Aluminium to aluminium
Aluminium cable on an aluminium terminal takes an aluminium lug.
Aluminium to copper
Aluminium cable on a copper terminal takes a bimetallic lug: aluminium barrel, copper palm.
Questions buyers ask
What is a cable lug?+
A cable lug is the fitting crimped, soldered or bolted onto the end of a cable so it can be bolted to a terminal, busbar or stud. The barrel holds the conductor and the palm carries the bolt hole.
When do I need a bimetallic lug?+
When an aluminium cable lands on a copper terminal or busbar. The bimetallic lug has an aluminium barrel for the cable and a copper palm for the terminal, so the two metals meet inside a sealed joint instead of at the bolt.
What do you check on every batch?+
Drawing dimensions, hole position and plating thickness, measured against your drawing, with conductivity where you specify it. A crimped joint fails on a burr or a hole that is a fraction out, so that is what we measure.
When should I use a brass lug?+
Brass is stronger than copper and easy to machine and solder, so it suits soldering lugs, small terminals and earth connections. It conducts about a quarter as well as copper, so high-current power cables take copper lugs.
Can you make lugs to a DIN standard?+
Yes, where your drawing names the standard, such as DIN 46235 for compression lugs. Send the drawing or the standard part number and we confirm what can be held before we quote.
Can you match an existing lug from another supplier?+
Yes. Send the drawing, and a sample if the drawing is incomplete. We tell you what can be held before we quote, then make samples for your approval.
Can you take a small order?+
Yes. Small, engineering-heavy batches are work we take, from prototype quantities upwards.
Send the drawing
Email us your enquiry at contact@qumek.com. We respond within 12 hrs.
Your enquiries are confidential with us and we proceed with manufacturing only after signing a NDA.
Need a DFM review, a prototype or a test plan before production? See the services.