26 August 2026
A recent solar farm project in Victoria ran into a problem that many large projects face.
The specified termination points didn't suit standard lugs.
With hundreds of connections still to be completed, changing equipment wasn't practical and waiting for an alternative wasn't an option.
The contractor needed a solution that would fit the available space, meet the project requirements and arrive asap, preferably yesterday!
ECL worked with the project team to develop a custom bimetal lug specifically for the application. The design featured a narrow palm and narrow barrel profile to suit the available termination space while still delivering the required performance.
Custom compression dies were also produced to ensure the correct compression ratio could be achieved during installation.
The solution was tested, approved and supplied in time to keep the project moving.
Just as importantly, ECL supplied the order in stages so product was arriving on site as it was needed, rather than waiting for the entire order to be completed before shipment.
It's a good example of where the challenge isn't finding a lug. It's finding a lug that actually fits the cable, is within the compression ratio tolerances, complies with local standards AND can be delivered very quickly.
We've seen this issue more than once on renewable energy projects. Many connectors are manufactured for overseas markets and don't always match the cable or comply with standards being used in Australia and New Zealand.
In those situations, an off-the-shelf product often doesn’t work.
Sometimes the best outcome comes from modifying the design, producing custom tooling and working directly with the contractor to solve the problem.
Whether it's solar, battery storage, industrial or utility infrastructure, our team regularly assists with custom connector solutions, specialised compression tooling and project-specific supply requirements.
If you've got a connection or termination that's proving difficult to solve, get in touch. We'd be keen to have a look at it for you!