Tension clamp for Overhead Lines

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Description

 

A Tension Clamp, also known as a dead-end clamp or strain clamp, is a critical mechanical fitting used in overhead power transmission and distribution lines to anchor and securely hold conductors under mechanical tension. These clamps are installed at line terminals, angles, or section points where the conductors must withstand pulling forces due to their own weight, wind, and mechanical load.

Available in bolted, wedge, or compression types, tension clamps are used in medium-voltage (MV) and high-voltage (HV) systems for industrial, utility, and infrastructure projects.

Tension clamp for Overhead Lines (strain clamp, dead-end clamp) refers to the metal fittings used to fix the wires to bear the tension of the wires and hang the wires to the strain strings or towers.

According to the design, the tension clamp is divided into Wedge type tension clamp, Cone tension clamp, Compression dead end clamp, Bolted type tension clamp.

Tension clamps are used for corners, splices, and terminal connections. Spiral aluminum-clad steel wire has extremely strong tensile strength, no concentrated stress, and plays a role in protection and auxiliary vibration reduction for optical cables. A complete set of cable tension fittings includes: tension pre-twisted wire, supporting connection fittings. The gripping force of the cable clamp is not less than 95% of the rated tensile strength of the optical cable. The installation is convenient and fast, and the construction cost is reduced. Suitable for ADSS optical cable lines with a span of ≤100 meters and a line angle of <25°.

 

Features

  1. The special design of the strain clamp enables it to be well matched with other power fitting components on the transmission line.
  2. The clip has high strength and reliable grip. The grip strength of the clamp is not less than 95% CUTS (calculated breaking force of stranded wire).
  3. The stress distribution of the wire clip on the twisted wire is even, without damaging the twisted wire, which improves the anti-vibration ability of the twisted wire and greatly prolongs the service life of the wire.
  4. Simple installation and convenient construction. The construction time can be greatly shortened, and the operation can be completed by one person without any special tools.

Good corrosion resistance, high-quality materials are selected. The material is exactly the same as that of the wire, which ensures that the clamp has a strong ability to resist electrochemical corrosion.

Parameters

 

Typical Technical Specifications

Parameter Specification Range
Rated Voltage 1kV to 500kV systems
Conductor Type ACSR, AAC, AAAC, copper, covered/insulated
Conductor Diameter Range 5 mm – 50 mm (customizable)
Rated Tensile Load Up to 90kN or higher based on model
Materials Galvanized steel, aluminum alloy, stainless steel
Surface Finish Hot-dip galvanized or anodized for corrosion protection
Operating Temperature -40°C to +80°C or higher
Standards IEC 61284, ANSI C119.4, GB/T 2314

 

Bolted type strain clamp

NLL is suitable for aerial lines up to 35kV, fixing stranded aluminum wire, steel-cored aluminum strand on the strain pole, or aerial insulated aluminum conductor. Smooth surface makes a long service life. Easy installation. No waste of electric energy.

 

Type Conductor Diameter (mm) Dimensions (mm) Rated Failure Load (KN)
L I C d
NLL-1 5.1-11.4 125 110 18 16 40
NLL-2 11.4-16 175 186 20 16 40
NLL-3 14.5-17.5 190 205 22 16 70
NLL-4 18-22.4 300 285 30 18 90
NLL-5 23-30 445 345 36 24 120

 

Tension Clamps

XGH type suspension clamp

Model Application Conductor (mm) Dimension (mm) Rated Failure

Load (KN)

H C D R L
XGH-2 5.1-12.5 52.5 25 16 18 166 40
XGH-3 12.4-17 50.5 23 16 11.5 200 40
XGH-4 19.0-23.5 50.5 27 16 13.5 225 40
XGH-5 24.2-28.0 70 32 16 16 260 60

Tension Clamps

Solutions

 

Common applications:

  • Anchoring phase conductors at tower ends and turning points
  • Terminal connections at substations and transformers
  • Power line crossings, angles, and tension sections
  • Renewable energy overhead lines (solar/wind farm feeders)
  • Rural and industrial grid infrastructure
  • Distribution lines in mining, oil & gas, and heavy industry

 

Key Features of Tension Clamps for Industrial Overhead Lines

Feature Benefits for Overhead Power Systems
High Tensile Strength Withstands long spans and heavy conductor loads
Corrosion Resistance Made from hot-dip galvanized steel or aluminum alloy
Mechanical Reliability Ensures long-term stability in varying environmental conditions
Multiple Types Available Bolt type, wedge type, compression type for different conductor specs
Wide Conductor Range Supports ACSR, AAC, AAAC, and other overhead conductor types
Easy Installation Suitable for field use with standard tools or hydraulic crimpers
Standards Compliant Meets IEC, ANSI, ASTM, GB/T mechanical and electrical standards

 

Why Use Tension Clamps in Overhead Line Construction?

✅ 1. Mechanical Security

Tension clamps ensure safe anchoring of the conductors, especially at dead-end poles, where high mechanical load is concentrated.

✅ 2. Weather Durability

Galvanized or anodized materials provide long-term protection against corrosion, UV, moisture, and chemical exposure.

✅ 3. Low Maintenance

Properly installed clamps require no routine maintenance, making them ideal for remote or hard-to-access areas.

✅ 4. Versatility

Compatible with a variety of conductor materials and sizes, tension clamps are used across voltage levels and geographic regions.

 

Tension Clamps vs Suspension Clamps

Comparison Tension Clamp Suspension Clamp
Function Holds and anchors conductors under tension Supports conductors under gravity load
Positioning End points, angles, terminal towers Intermediate poles, long straight sections
Installation Force Withstands high axial tension Supports vertical weight of the cable
Usage Dead-end, strain sections Sagging, vibration control

Tension clamps are a must-have in any robust overhead line system where conductor pull and directional change occur.

Benefits of Choosing Our Tension Clamps

  • Proven mechanical strength and field reliability
  • Quick and secure installation with standard tools
  • Corrosion-resistant for harsh climates and coastal zones
  • Compatible with a wide range of cable types and line geometries
  • Available in bulk with flexible packaging for large-scale projects

 

Order Tension Clamps for Overhead Lines Today

We manufacture and supply tension clamps for ACSR, AAC, AAAC, and covered conductors, designed for 1kV to 500kV overhead power systems.

  • Standard models and custom-engineered clamps available
  • Certified to IEC, ANSI, and GB/T standards
  • Technical consultation and installation support included
  • Fast delivery for EPCs, utilities, and transmission contractors.