26 August 2026
In overhead networks, tap connections are everywhere. They might be a small part of the overall line design, but when a connection fails or is installed incorrectly, the consequences can be expensive.
Extra truck rolls, additional outage planning, crew time, and safety exposure all add up. That's why choosing the right tap connector matters.
One of the most common connector types used across overhead networks is the Parallel Groove Clamp (PG Clamp). However, not all PG Clamps are the same, and selecting the wrong type for the conductor or application can create problems down the track.
Not All PG Clamps Are Created Equal
Today's networks contain a mix of conductor types and materials, including aluminium, copper, insulated conductors, and aluminium-to-copper transitions.
The connector needs to match the conductor type and the application.
At ECL, we supply a range of tap connectors designed for common utility applications, including aluminium, copper, insulated conductors, and bimetallic connections.
Common Applications
Aluminium to Aluminium Connections
For tap-offs on aluminium conductors, Aluminium Parallel Groove Clamps are a proven solution for creating reliable electrical connections.
Aluminium to Copper Connections
Where aluminium mains connect to copper conductors, Bimetallic Parallel Groove Clamps help manage the transition between dissimilar metals and reduce the risk of long-term issues.
Covered Conductor Applications
For aluminium conductors with copper tap-offs in covered conductor systems, Bimetallic Cover Type Tap Connectors provide a purpose-designed solution.
Dead Ends and Auxiliary Conductors
Universal Overhead Line Clamps are commonly used for dead ends, tap-offs, and auxiliary conductor applications on aluminium overhead networks.
Copper Networks
Copper Parallel Groove Clamps are designed specifically for copper-to-copper connections.
Insulated Conductors
Where insulated conductors are used, Insulation Piercing Connectors (IPCs) can eliminate the need to strip insulation, helping crews work faster while maintaining connection integrity.
Five Things to Check Before Specifying a Connector
1. Conductor Material
Always confirm the conductor material on both sides of the connection. Aluminium-to-aluminium and aluminium-to-copper applications require different solutions.
2. Application
Is it a tap connection, dead end, or auxiliary conductor application? Selecting a connector based on the actual use case helps avoid problems later.
3. Insulated or Bare Conductor
Insulation Piercing Connectors can be a practical option where insulation removal is undesirable or time consuming.
4. Installation Consistency
In the field, different crews and different linemen often deliver different results. Products that provide controlled tightening can help improve consistency across a network.
5. Long-Term Durability
Materials, corrosion resistance, and contact protection all play an important role in ensuring reliable performance over the life of the connection. We also see a lot of coastal corrosion, so protecting/covering in these areas where practical is good.
The Cost of Getting It Wrong
We've all seen situations where a connector was selected because it was available on the truck or ute rather than because it was the right product.
Most of the time it works, but sometimes it doesn’t…
When a connection needs to be revisited, the cost is rarely limited to the connector itself. Additional crew time, outage requirements, travel, and admin quickly outweigh the cost of selecting the right product in the first place.
Need Help Selecting the Right Connector?
Our utility team can help identify the most suitable tap connector for the application.
Simply provide the conductor details and installation requirements, and we'll recommend a solution to suit.