Brass Square Tape Clamps

Brass Square Tape Clamps

Brass square tape clamps — also called brass tape connectors, copper tape square clamps, or flat tape bonding clamps — are precision-machined or cast brass fittings with a square-profile conductor channel, designed to mechanically connect, splice, or terminate flat copper tape conductors in earthing systems, lightning protection installations, and equipotential bonding networks. Manufactured by Electrical Accessories India (Jamnagar) from leaded brass CW614N and dezincification-resistant (DZR) brass CW602N, these clamps are the cost-effective alternative to bronze square tape clamps for above-ground installations where soil burial is not required. They cover tape sizes from 25 mm × 3 mm to 50 mm × 6 mm, conform to IS 3043, BS 7430, and IEC 62305-3, and are suitable for use in a wide range of industrial, commercial, and utility earthing and lightning protection projects.

Product Overview

Square-Profile Channel Design for Copper Tape

Brass square tape clamps feature a rectangular (square-profile) internal channel precisely matched to the width and thickness of the copper tape conductor. This geometry prevents tape rotation, pullout, and misalignment — problems that arise when flat tape is forced into round-conductor clamps. Two or four bolts (silicon bronze or SS316) clamp a top pressure plate against the tape’s upper face, distributing force uniformly across the full tape width and achieving maximum conductor contact area. The square-profile internal bore eliminates point loading on the tape, preventing strand or edge damage that would increase contact resistance over time. For above-ground installations in substations, buildings, cable trays, and equipment earthing connections, brass square tape clamps provide a reliable, cost-effective bolted joint. Related terms: square tape connector, flat tape clamp brass, copper strip connector, brass tape bonding clamp, copper tape splice connector, earthing tape joint brass.

Material: Leaded Brass CW614N and DZR Brass CW602N

Brass square tape clamps are manufactured in two alloy options. Standard CW614N leaded brass (IS 319 Grade 1, ASTM B16 C36000, BS EN 12164) is the primary material — free-cutting, dimensionally consistent, and cost-effective for high-volume machining. For environments where dezincification is a risk (coastal locations, industrial atmospheres, high-humidity indoors), dezincification-resistant (DZR) brass CW602N (ASTM B283 C35330, BS EN 12165) is specified. DZR brass contains arsenic inhibitors that prevent the selective leaching of zinc from the brass matrix in corrosive conditions, extending service life without the full cost of silicon bronze. Clamping hardware (bolts, pressure plates, washers) is supplied in SS316 stainless steel or silicon bronze. For buried tape joints, see our Bronze Square Tape Clamps product page — brass is not recommended for direct burial. Related standards: BS EN 12164 CW614N, BS EN 12165 CW602N, IS 319, ASTM B16, ASTM B283.

Tape Size Range and Dimensional Matching

Brass square tape clamps are produced to match standard copper tape cross-sections specified in IS 3043, IEC 62305-3, and BS 7430. Standard tape sizes covered: 25×3 mm, 25×4 mm, 32×3 mm, 32×6 mm, 40×4 mm, 40×6 mm, 50×6 mm. Channel width is machined to tape width ±0.2 mm — tight enough to prevent tape movement yet allowing insertion without forcing. Channel depth accommodates the tape thickness plus the pressure plate, ensuring the bolt travel is sufficient for full clamping. The clamp body length provides adequate conductor engagement (minimum 1.5× tape width) for mechanical pull-out resistance. Custom tape channel sizes for non-standard dimensions are machined to customer drawing within standard lead times. Related terms: 25×3 brass tape clamp, 40×4 copper tape connector, 50×6 mm flat tape clamp, BS 7430 tape connector, IS 3043 copper tape clamp.

Connection Functions and Joint Types

Brass square tape clamps serve the same connection functions as the bronze variants, but optimised for above-ground service. Primary connection types: (1) Straight splice — two lengths of copper tape joined end-to-end in a continuous earthing ring conductor; (2) T-junction — branching a tap-off conductor from the main ring at 90°, used at equipment earthing points; (3) Tape-to-terminal — connecting a copper tape conductor to a bolt-on earthing terminal, transformer ground lug, or equipment earth stud; (4) Tape-to-busbar — flat-face bolted connection to copper or aluminium earthing busbars; (5) Cross-junction — connecting two crossing tapes at 90° in a grid earthing layout. Each joint type has a specific clamp body geometry; specify connection type when ordering. Related terms: tape splice joint, tape T-connector, tape cross-joint, tape terminal connector, earthing tape bonding clamp.

Structural and Mechanical Performance

Brass square tape clamps must maintain the electrical and mechanical integrity of the tape joint over the full service life of the earthing installation — typically 25 to 40 years. The clamp body and bolts are designed to provide a conductor pull-out force exceeding 1.5× the tensile load expected on the tape conductor under design conditions. Bolt torque is selected to maintain conductor contact pressure without yielding the brass body. Thermal cycling between -20°C and +80°C over the installation life should not loosen the joint — periodic re-inspection and re-tightening every 5 years is recommended per IS 3043 and IEEE Std 80 maintenance schedules. Self-locking bolt variants (Nyloc SS316) are available to minimise loosening risk in vibration-prone environments. Related terms: tape clamp pull-out strength, earthing joint maintenance, tape connector thermal cycling, long-term contact resistance.

Brass vs Bronze Square Tape Clamps: Selection Guidance

Brass (CW614N or CW602N) square tape clamps are the preferred choice for: above-ground installations in non-aggressive environments, cost-sensitive large volume projects, indoor earthing in clean environments, and installations where periodic access for inspection and re-tightening is feasible. Bronze (silicon bronze C65100 or LG2 CC491K) square tape clamps should be specified for: direct-buried earthing ring conductors, coastal or marine environments, chemical plant earthing, and ATEX Zone 1/2 installations requiring non-sparking materials. Both product families are manufactured to the same dimensional standards and tape channel geometries, ensuring interchangeability where specification changes are required during a project. Related terms: brass vs bronze tape clamp, CW614N vs C65100 clamp, above ground vs buried tape connector selection.

Key Features

• Square-profile brass conductor channel matched to copper tape cross-section
• Available in leaded brass CW614N (standard) and DZR brass CW602N (corrosion-resistant)
• Tape sizes: 25×3 mm to 50×6 mm standard; custom sizes machined to drawing
• 2 or 4 SS316 or silicon bronze clamping bolts for even pressure distribution
• Connection types: straight splice, T-junction, tape-to-terminal, tape-to-busbar, cross-junction
• For above-ground installations — use bronze tape clamps for buried applications
• Compliant: IS 3043, BS 7430, IEC 62305-3 for above-ground tape connections
• Nyloc self-locking bolt variant available for vibration-prone environments
• Cost-effective alternative to bronze clamps for surface-mount installations
• Full material certification and dimensional documentation for project specifications

Material Grades and International Equivalents

Technical Specifications

Product Types and Variants

• Straight Splice Brass Clamp: Two-piece body for in-line tape-to-tape joining; 2 or 4 bolts
• T-Junction Brass Clamp: 90° branch connection from main tape conductor
• Tape-to-Terminal Brass Clamp: Square tape channel + bolt-on terminal face for equipment earthing point connections
• Tape-to-Busbar Brass Clamp: Flat base face for bolting to copper or aluminium earthing busbars
• Cross-Junction Brass Clamp: Four-way crossing tape clamp for earthing grid layouts
• DZR Variant: CW602N DZR brass body for humid or coastal above-ground environments
• Nickel-Plated: Enhanced finish for visible architectural or panel installations

Applications in Industry

• Building Lightning Protection: Down conductor tape splice joints and T-junction connections per IEC 62305-3 / BS EN 62305-3
• Substation Earthing (Above-Ground): Above-ground earth ring tape splice joints; busbar tape bonding connections per IS 3043 / IEEE Std 80
• Transformer Earthing: Copper tape terminations at transformer body earthing studs and neutral earthing connections
• LV Panel / MCC Earthing: Copper tape bonding within LV distribution panels and motor control centres
• Industrial Earthing: Structural steel bonding via copper tape joints; static earthing connections in process areas
• Telecom / Data Centres: Copper tape bonding clamps in below-raised-floor earthing grids and overhead cable tray earthing systems
• Solar PV Systems: DC grounding copper tape splice connections for module mounting structure bonding
• Hospital Earthing: Supplementary equipotential bonding tape connections in clinical areas per IEC 60364-7-710

Manufacturing Process

1. Material: CW614N or CW602N brass bar stock with mill test certificate per BS EN 12164 / BS EN 12165
2. Sawing: Bar cut to clamp blank lengths on CNC circular saw
3. CNC Milling: Tape channel milled to tape width ±0.2 mm and tape thickness + clearance; external form milled to drawing
4. Drilling and Threading: Bolt holes drilled and tapped; fixing/mounting holes drilled where specified
5. Deburring: Barrel tumbling or hand deburring; all edges and internal channel radiused to prevent tape strand damage
6. Plating: Nickel or tin electroplating applied where specified per customer finish requirement
7. Dimensional Inspection: Channel width, depth, bolt hole pitch and thread verified per drawing
8. Packing: Complete assembly (body + pressure plate + bolts + washers) in poly bag; bulk carton with MTC and certificate of conformance

Quality Standards and Certifications

• IS 3043 – Code of Practice for Earthing (India)
• BS 7430 – Code of Practice for Protective Earthing (UK)
• IEC 62305-3 – Physical Damage to Structures and Life Hazard (Lightning Protection)
• BS EN 12164 – Copper Alloy Rod for Free Machining (CW614N)
• BS EN 12165 – Copper Alloy Wrought Products (DZR CW602N)
• ASTM B16 / ASTM B283 – Brass Rod and DZR Brass
• IEEE Std 80 – Guide for Safety in AC Substation Grounding
• ISO 9001:2015 – Quality Management System
• RoHS Compliant

Why Choose Electrical Accessories India

• Complete brass and bronze tape clamp range from one manufacturer — consistent quality, simplified procurement
• Both CW614N standard brass and DZR CW602N brass available in all tape sizes
• Tape channel machined to ±0.2 mm — no tape damage, full-face contact guaranteed
• All connection types: straight splice, T-junction, terminal, busbar, cross-junction
• Nyloc and standard bolt variants for vibration-sensitive and standard installations
• Custom tape channel sizes and special configurations machined to drawing within 2–3 weeks
• Complementary bronze square tape clamps available for buried applications — same tape size range
• Export to 30+ countries with full MTCs, dimensional reports, and RoHS declarations

Frequently Asked Questions (FAQ)

What is a brass square tape clamp and how does it differ from a DC clip?

A brass square tape clamp is a bolted, permanent connection fitting for copper tape conductors, providing a full mechanical and fault-current-rated electrical joint. A DC clip is a lighter-duty spring or single-bolt fitting used primarily for tape fixing and light electrical continuity. For structural, permanently bolted tape-to-tape or tape-to-terminal joints, use the square tape clamp. For tape fixing clips along a run, use DC clips.

Can brass square tape clamps be used underground or in buried earthing grids?

Standard brass (CW614N and CW602N) tape clamps are not recommended for direct burial. Brass is susceptible to dezincification in buried soil conditions, particularly in acidic, saline, or high-moisture soils. For buried tape joints, specify our Bronze Square Tape Clamps in silicon bronze C65100 or gunmetal LG2 (CC491K), which are designed for direct-buried service.

What copper tape sizes are compatible with your brass square tape clamps?

Standard sizes: 25×3, 25×4, 32×3, 32×6, 40×4, 40×6, and 50×6 mm. Custom sizes machined to drawing. For tape widths exceeding 50 mm or thicknesses above 6 mm, contact us for custom clamp specifications.

What bolt material is supplied with the brass square tape clamps?

Standard supply is SS316 stainless steel hex-head bolts, spring washers, and flat washers. Silicon bronze bolts can be substituted for full bi-metallic compatibility in corrosive environments. Nyloc SS316 self-locking bolts are available for vibration-prone or high-cycling applications.

Do you supply T-junction and cross-junction brass tape clamps?

Yes. T-junction (90° branch) and cross-junction (four-way) brass tape clamp bodies are available in the same tape size range as straight splice clamps. Specify connection type when ordering. Mixed packs for project-specific joint type combinations can be quoted.

What is the difference between CW614N and CW602N DZR brass for tape clamps?

CW614N is standard leaded free-cutting brass — cost-effective and suitable for the majority of indoor and above-ground installations in mild environments. CW602N DZR brass contains arsenic additions that prevent dezincification in humid, coastal, or mildly corrosive atmospheres. Specify DZR for any installation where moisture or humidity may be a long-term risk, even if not buried.

Are your brass tape clamps suitable for lightning protection down conductor tape joints?

Yes. Brass square tape clamps are used for tape splice joints in lightning protection down conductors per IEC 62305-3 for above-ground sections. Where the tape run goes underground, switch to bronze square tape clamps for the buried section joints.

Can the same tape clamp body be used for both 25×3 mm and 25×4 mm tape?

No. The channel depth is matched to the tape thickness — a 25×3 mm clamp channel is shallower than a 25×4 mm clamp. Using the wrong depth clamp will either not clamp the tape (too deep) or not close fully (too shallow). Always specify both tape width AND tape thickness when ordering.

Equivalent Terms – Multilingual Reference

Related Products and Linked Terms

• Copper Bonded Earth Rods
• Bronze Ground Rod Clamps
• Bronze Copper Grounding Clamps
• Bronze Grounding Pipe Clamps
• Earth Tags Brass
• Brass Earth Blocks
• Brass A Clamps
• DZR Brass Machined Parts
• Brass Castings
• Bronze Ground Rod Couplers

Request a Quote

To request pricing for brass square tape clamps, specify: tape size (width × thickness in mm), connection type (straight splice / T-junction / terminal / busbar / cross-junction), material (CW614N standard or CW602N DZR brass), bolt material (SS316 or silicon bronze), bolt type (standard hex or Nyloc), and quantity.

Contact us: Send your RFQ with tape dimensions, connection type, and quantity. We respond within 24 business hours. Full export documentation provided: MTCs, certificate of conformance, RoHS declaration, Packing List, and Certificate of Origin.