Aluminum Wedge Connectors, Aluminum Bolted Wedge Connectors
Bolted Connectors | Aluminum Wedge Connectors for Overhead Distribution
Manufacturer & Exporter from India | Supplying USA Utilities, EPCs & OEMs
Aluminum Bolted Wedge Connectors – Overview (USA Utility Grade)
We are a manufacturer and exporter of Aluminum Bolted Wedge Connectors, Bolted Connectors, and Aluminum Wedge Connectors used in overhead electrical distribution systems. Our connectors are designed for mechanical reliability, electrical continuity, and long-term outdoor service, meeting the expectations of USA utility and industrial power networks.
Bolted wedge connectors are widely used for tap connections on AAC, AAAC, and ACSR conductors, providing a controlled mechanical interface without crimping. These connectors are suitable for primary and secondary distribution voltages, subject to conductor size and application.
Country of Origin: India
Export Market Focus: United States (North America)
Typical Production Lead Time: 4–6 weeks
What Is an Aluminum Bolted Wedge Connector?
An Aluminum Bolted Wedge Connector is a mechanical tap connector made from Aluminum casting that uses a wedge element and bolted clamping system to secure a tap conductor to a main overhead conductor.
The wedge geometry develops contact pressure when tightened, while the bolted assembly allows:
- Controlled installation torque
- Consistent mechanical loading
- Repeatable field installation
- Visual inspection after installation
These connectors are commonly selected where crimping is impractical, where field installation reliability is critical, or where maintenance access is required.
Typical USA Applications
- Overhead utility distribution lines
- Primary and secondary tap connections
- Industrial overhead power systems
- Aluminum-to-Aluminum conductor taps
- Aluminum-to-Copper taps (when specified)
- Maintenance, repair, and network expansion work
Final suitability depends on conductor material, strand construction, and diameter range. Customer confirmation is required prior to production.
Product Range
Aluminum Wedge Connectors
- Cast or machined aluminum bodies
- Precision-machined wedge interfaces
- Designed for stable conductor capture
- Compatible with oxide-inhibiting compounds
Aluminum Bolted Wedge Connectors
- Complete assemblies including bolt, nut, and washers
- Torque-controlled installation
- Suitable for overhead tap connections
- Designed for outdoor service conditions
Custom Bolted Connectors (OEM)
- Manufactured as per customer drawings or samples
- Prototype and first-article development supported
- Batch production with traceability
- Export packaging for USA delivery
Materials & Alloys Used
Material selection is based on electrical conductivity, mechanical strength, corrosion resistance, and manufacturability. We have Aluminum die casting and Aluminum shell molding facility offering high quality Aluminum castings from our Aluminum casting foundry in India/
|
Component |
Typical Materials |
Application Rationale |
|
Connector Body (Cast) |
A356 / A356-T6 Aluminum |
Structural strength and casting stability |
|
Wedge / Interface Parts |
6061-T6, 6063-T6 Aluminum |
Dimensional control and clamping integrity |
|
High-Conductivity Aluminum |
6101, 6201 |
Used where electrical performance is critical |
|
Bolts & Hardware |
SS304, SS316, zinc-plated steel |
Mechanical strength and corrosion resistance |
|
Surface Treatment |
Anodizing, conversion coating |
Outdoor corrosion mitigation |
Final alloy and coating are confirmed based on conductor material, environment, and customer specification.
Manufacturing Capabilities
- Aluminum casting (controlled gravity processes), Die casting, Shell molding (Resin sand casting)
- CNC & VMC machining for wedge and bolt interfaces
- Controlled tolerances on contact surfaces
- Hardware assembly and inspection
- Lot-wise traceability and marking
- Export-ready packaging and labeling
Quality & Inspection (Utility-Focused)
Quality is managed per project-specific inspection criteria, including:
- Incoming material verification
- Dimensional inspection using gauges and fixtures
- Surface finish and coating verification
- Assembly inspection (bolt engagement and fitment)
- First Article Inspection (FAI) documentation (on request)
- Third-party testing coordination when required
Why Conex?
- Experienced manufacturer supplying the USA power sector
- Engineering-driven approach to connector design and production
- Flexible support for prototypes and volume production
- Clear documentation and export compliance
- Competitive manufacturing base with consistent quality
Technical Characteristics
- Wedge-based mechanical locking mechanism
- Stable electrical interface under load
- Compatible with anti-oxidation compounds
- Suitable for outdoor exposure (rain, UV, temperature variation)
- Tool-friendly bolted installation
Frequently Asked Questions (USA Buyers)
Do you manufacture Aluminum Bolted Wedge Connectors in India?
Yes. All manufacturing is carried out in India and supplied to USA customers.
Are your connectors suitable for Aluminum-to-Copper connections?
Yes, when specified. Proper interface design and inhibitor use are essential.
Which conductor types are supported?
AAC, AAAC, ACSR, and similar overhead conductors.
What aluminum grades are used?
Common grades include A356, 6061, 6063, 6101, and 6201.
Do you supply complete assemblies?
Yes, including bolts, nuts, and washers per specification.
What is the standard lead time?
Typically 4–6 weeks, depending on quantity and tooling status.
Can you manufacture to customer drawings?
Yes. OEM manufacturing as per drawing or approved sample is supported.
Do you offer wedge connectors in Bronze or Aluminum bronze?
Yes, we also offer Bronze Wedge Connectors and Bolted bronze Connectors.
Request for Quotation (RFQ)
Please provide by email:
- Drawing, photo, or sample reference
- Main conductor material and size range
- Tap conductor material and size range
- Aluminum-Aluminum or Aluminum-Copper interface
- Quantity requirement
- Surface treatment / coating requirement
- Documentation needs (FAI, CoC, test reports)
Delivery location in the USA