HEX Worldwide manufactures a comprehensive range of electrical lugs for power distribution, switchgear, industrial wiring, and infrastructure applications. With over 30 years of precision manufacturing experience and ISO 9001 certification, our cable lugs are engineered to deliver reliable, low-resistance terminations across conductor sizes from 1.5 mm² to 630 mm².
Our electrical lugs are supplied to leading EPC contractors, OEM panel builders, and infrastructure developers across India and in export markets including the Middle East, Southeast Asia, Europe, and Africa.
HEX Worldwide’s electrical lug portfolio covers every major conductor material, termination configuration, and industrial application requirement. Each product line is manufactured to applicable Indian and international standards.
Our copper cable lugs are manufactured from high-conductivity electrolytic copper (99.9% purity), available in crimping type and compression type configurations. The barrel is precision-formed for consistent wall thickness and optimal crimping performance.
Available variants:
Standards: IS 8309 | DIN 46235 | BS 4579
Conductor range: 1.5 mm² – 630 mm²
Pin type lugs provide a compact, vibration-resistant termination for switchgear, MCCBs, ACBs, and DIN rail terminal blocks. The pin barrel enables direct insertion into terminal sockets without requiring a flat seating area, making them the preferred choice for control panel wiring.
Available variants:
Standards: IEC 60947 | IS 8309
Conductor range: 0.5 mm² – 50 mm²
Manufactured from high-grade aluminium alloy, our aluminium cable lugs are designed for use with aluminium conductors in overhead lines, distribution transformers, and heavy power applications where weight is a consideration.
Available variants:
Standards: IS 8309 | IEC 61238-1
Conductor range: 16 mm² – 630 mm²
Where corrosion resistance is critical — marine environments, coastal installations, chemical plants, or high-humidity enclosures — our electro-tinned copper lugs provide a protective tin coating that prevents oxidation at the contact interface without compromising conductivity.
Available variants:
Standards: IS 8309 | BS 4579
Conductor range: 4 mm² – 400 mm²
Multi-hole lugs are specified for high-current busbar connections where mechanical stability and current distribution across multiple contact points are required. Four-hole variants are commonly used in switchgear panels, distribution boards, and transformer secondary connections.
Available variants:
Standards: IS 8309 | DIN 46235
Conductor range: 25 mm² – 630 mm²
All HEX electrical lugs are manufactured and tested in accordance with the following standards:
| Standard | Scope |
|---|---|
| IS 8309:2004 | Indian Standard for Compression Type Cable Lugs |
| DIN 46235 | German Standard for Copper Cable Lugs for Crimping |
| BS 4579 | British Standard for Performance of Mechanical and Compression Joints |
| IEC 61238-1 | Compression and Mechanical Connectors for Power Cables |
| IEC 60947 | Low-Voltage Switchgear and Controlgear (Pin Lugs) |
Our in-house quality control laboratory verifies dimensional accuracy, mechanical pull-out strength, contact resistance, and current-carrying capacity for every production batch.
| Parameter | Specification |
|---|---|
| Conductor material compatibility | Copper (Cu), Aluminium (Al), Copper-clad Aluminium (CCA) |
| Conductor size range | 1.5 mm² – 630 mm² (product-dependent) |
| Material — copper lugs | Electrolytic copper, min. 99.9% purity, IACS ≥ 97% |
| Material — aluminium lugs | Aluminium alloy, 1350-H19 grade |
| Surface finish options | Bare copper, electro-tinned, electro-silver plated (on request) |
| Temperature rating | –40°C to +105°C (continuous operating temperature) |
| Voltage class | Up to 1 kV (LV applications) |
| Crimping method | Hexagonal crimp, oval crimp, indent crimp (die-set specific) |
| Hole diameter range | M6 to M16 (bolt-hole, palm area) |
HEX electrical lugs are specified across a broad range of power and industrial applications:
Power Distribution & Transmission Transformer LV terminal connections, MV/LV switchgear panels, distribution boards, bus ducts, and cable termination kits for XLPE and PVC insulated cables.
Industrial Installations Motor control centres (MCCs), variable frequency drives (VFDs), control panels, cable management systems in process plants, refineries, and manufacturing facilities.
Infrastructure Projects Railway electrification (25 kV AC traction), metro rail systems, airport electrical systems, data centre power distribution, and renewable energy (solar and wind power plant cabling).
Original Equipment Manufacturers (OEMs) Switchgear manufacturers, transformer manufacturers, generator set manufacturers, and panel builders specifying lugs as a standard BOM component.
Export Markets HEX copper and tinned copper lugs are supplied to contractors and distributors in the UAE, Qatar, Saudi Arabia, Singapore, Kenya, and the UK under international standard specifications.
Manufacturing Depth HEX Worldwide is a direct manufacturer — not a trader. Our Brass Copper & Alloy (I) Ltd. manufacturing facility has over 30 years of precision non-ferrous metal fabrication experience, giving us full control over material sourcing, dimensional tolerances, and surface treatment quality.
ISO 9001 Certified Quality System Every production lot is subject to documented incoming material inspection, in-process dimensional checks, and finished-goods pull-out force and contact resistance testing. Certificate and test reports available on request.
Traceable Raw Materials Our copper rod stock is sourced from certified smelters with full material traceability. This is critical for projects requiring material certificates under IS 8309 Annex compliance or third-party inspection.
Trusted by Tier-1 Clients ABB, Siemens, L&T, and other marquee EPC and OEM clients have been procuring HEX lugs as approved vendor supply for major infrastructure projects across India.
Supply Reliability for Large Volumes With in-house tooling, multi-press production lines, and local raw material procurement, we support bulk MOQ orders with consistent lead times — essential for large project procurement schedules.
Complete Accessory Ecosystem HEX also manufactures crimping tools calibrated for our lug die sets, ensuring correct crimp geometry and eliminating the risk of under- or over-crimping in the field.
Selecting the correct lug requires matching five critical parameters:
For applications involving aluminium conductors terminated into copper busbars or switchgear, always specify bimetallic lugs to prevent galvanic corrosion at the Al-Cu interface.
