3 Reasons Lugs Fail (And How to Ensure Yours Don't)
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What causes Lugs to failWhat causes Lugs to fail
Aug 2023 4 min read

3 Reasons Lugs Fail (and How to Ensure Yours Don't)

CABAC, as a part of Legend Corporation, operates a NATA (National Association of Testing Authorities, Australia) Accredited Laboratory at our Seven Hills plant in Sydney. It is here that CABAC's custom engineered and manufactured lugs are tested to the highest of standards. This accreditation means we guarantee the results from our custom made Lug (and other) testing and not just the system that produces them (as is the case for labs that only achieve certification).

Over the years we have seen lugs and links fail both inside and outside our NATA laboratory, and here are some of our key findings: 

How Can Electrical Lugs Fail?

  1. The lug can fail a tension test by breaking. This is rare but it has been known to happen.  A lug most commonly fails a tension test by failing to hold and secure a cable while it is under tension – in this instance we see the point at which the cable is secured by the lug undergoing significant slippage.   
  2. The lug simply cannot be crimped (compressed down) and fastened for the types of conductors or cables it is used to secure.  This means there is an issue with the composition of the lug or some other structural issue. 
  3. The lug fails the heat cycle test because the temperature of the lug exceeds a reference conductor which we also test during the course of our heat cycle testing.  A lug will fail the heat cycle test because the temperature and the resistance of the tested set of lugs has too great a variability – meaning the fitting becomes unstable.  

As part of our testing processes, CABAC lugs and links must pass three hurdles before they are accepted.  

  1. The dimensions and specifications of the lug must meet the design and dimensions of their engineering drawing within the tolerances specified.
  2. The lug must pass a tension test – ensuring it can hold and secure a cable when put under tension.
  3. Provided the lug successfully passes the tension test, only then do we move on to the heat cycle test. Once it passes the heat cycle test, we have three inspection and test results which give us confidence to declare that the lug type will be safe and effective to use in its defined applications.

Because of our testing cycle, the quality assurance programs and the high level of expertise of our NATA laboratory team, our lug designs provide the level of performance which is expected of these critical electrical components in the field, with the end to end process all happening here in Australia.

CABAC also uses our in depth knowledge of testing failures, as well as testing procedures to continuously improve both our testing procedures and the design and engineering of our custom made lug solutions. When you buy CABAC lugs, you’re not just buying the lug, you are buying years of learning and optimisation that has gone into creating the very best quality of custom manufacturing.

Make sure you know what you are buying and always buy from an Australian manufacturer of custom made lugs with a NATA ACCREDITED Laboratory, and don’t forget, CABAC engineers can work with you to build a custom solution for your specific project needs. 


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2023-08-09 00:48:00
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