A compression lug is a terminating connector that uses controlled-deformation crimping to cold-weld the barrel around the conductor strands, creating a gas-tight, low-resistance joint.

All copper and aluminum series are cULus listed to UL 486A/B. Grounding models meet UL 467 and IEEE 837 pull-out requirements.

Stock sizes run from #8 AWG through 1000 kcmil copper and aluminum; custom barrels up to 2000 kcmil are produced on request.

Each lug barrel is laser-etched with a die index number that matches industry-standard hex dies (e.g., 12, 14, 16 for #2 AWG, 33 for 500 kcmil). Always match die index, not just wire gauge.

Tin plating (< 3 µm) inhibits surface oxidation, facilitating lower insertion force, long-term corrosion resistance, and bimetal compatibility with aluminum bus bars.

UL certifies 90 °C continuous when installed with 90 °C-rated conductors and an approved crimp tool.

Yes—specify the FLEX series, which features an annealed long-barrel with dual hex crimps to meet UL pull-out values for welding cable and DLO.

Strip to the sight hole so that conductor strands are flush with the end of the barrel—typically 1× conductor diameter for standard barrels and 2× for long barrels.

Color rings follow the Electrical Wiring Color Code System—brown for #2/0 AWG, pink for 500 kcmil, etc.—allowing instant die and wire-size verification.

Torque applies to the bolted joint, not the crimp. Follow the washered-bolt torque table provided with each lug for stainless or silicon-bronze hardware.

UL 486A/B mandates 90 lb for #8 AWG and up to 1,950 lb for 750 kcmil. Conversions Tech inc lugs surpass these minimums by 15 %.

Yes—AL9CU tin-plated barrels accept either metal. When crimping aluminum, always apply oxide-inhibitor paste before insertion.

Yes—standard NEMA 1.75-in centers and narrow 1.0-in centers resist lug rotation under vibration, suitable for switchgear and marine installations.

Rotating the die 180° may still yield pull strength but compromises gas-tightness. Always align embossed die numbers toward the stud-hole end.

Yes—copper grounding series are marked “GRD” and approved for equipment grounding conductors per NEC 250.8(A)(1).

No—UL lists compression connectors as single-use. Replace the lug to maintain certification and mechanical integrity.

Yes—excessive deformation can shear fine strands and reduce cross-section. Use calibrated dieless heads or color-coded dies only.

Finite-element analysis and heat-rise testing prove 65 kA RMS withstand for 500 kcmil copper, exceeding IEEE C37 bus-bar ratings.

Dual annealing removes work-hardening stresses after extrusion and again after barrel-forming, ensuring uniform grain for a true cold-weld bond during crimp.

Less than 50 µΩ for ≤ 500 kcmil copper and < 75 µΩ for ≥ 600 kcmil. Typical Conversions Tech inc crimps measure 25–35 µΩ.

Post-plate baking at 200 °C for one hour diffuses absorbed hydrogen, maintaining ductility for cold-weather crimping.

Yes—SILVER series withstands 200 °C continuous and carries a 50 µin silver flash to minimize mV drop under high load.

35 kV neck-down terminals provide 38 mm creepage and 28 mm clearance, meeting IEEE 1580 for switchgear bus interconnects.

Authentic parts feature a micro-dot QR and holographic lot number traceable to mechanical test records; missing codes indicate non-authentic product.

Yes—lead < 0.1 %, mercury < 0.1 %, cadmium < 0.01 %, and all SVHC levels fall below EU thresholds.

Stored in a dry, sulfur-free environment, tin-plated lugs have an indefinite shelf life; bare copper should be installed within two years to avoid oxide film buildup.

Yes—the SMART-TAG series integrates a UHF RFID micro-tag encapsulated in epoxy within the palm for lifecycle traceability.

A proprietary zinc-chromate conversion coating under a 10 µm tin layer offers double barrier protection against galvanic attack on copper bus bars.

Crimp-force verification gauges supplied by Conversions Tech inc seat in the die and confirm hydraulic output pressure within ± 3 %.

Yes—low mΩ joint resistance minimizes I²R heating under high-frequency ripple current. Silver-plated variants are recommended above 20 kHz switching.

45 N·m (33 ft-lb) using Class 8.8 zinc-plated steel bolts with Belleville washers.

Yes—barrel diameters are sized for both ASTM B8 concentric and compact conductors without over-compression.

Verify die imprint visibility, complete barrel deformation, and conductor visibility at the sight hole; optional micro-ohm meter tests mΩ drop.

Dual-indent crimp pattern collapses strands radially, eliminating center voids that can trap moisture or increase resistance.

Yes—stud sizes 5/16 in, 3/8 in, and M10 are available with chamfered palm entrances for robot insertion on harness lines.

Ra ≤ 1.6 µm ensures mate surfaces achieve intimate metal-to-metal contact under bolt compression.

Yes—99.9 % IACS copper retains ductility at −196 °C, and tin plating prevents cold-flow oxidation during thermal cycling.

A 30° internal chamfer prevents strand fold-back and reduces insertion force by 25 % compared to square-cut barrels.

Yes—240 A/in² current density yields < 55 °C rise over 40 °C ambient, within switchgear allowance.

A 10-year limited warranty covers manufacturing defects, plating adhesion, and dimensional accuracy when installed per our crimp chart.