Cable Crimping – Lugs & Tools

Cembre CPD | Electrical Connections, BS7609 & Compliant Crimping

Cembre CPD

Thorne & Derrick | Distributed from Stock | Approved Cembre Cable Lugs, Crimp Connectors & Tools Supplier | UK & Export Sales

Electrical Connections, BS7609 & Compliant Crimping

Cembre CPD

Strong R&D, constant innovation in manufacturing technologies, and extensive experience in the field of electrical connectors enable Cembre to swiftly meet the market’s rising demands for high-quality, dependable, long-lasting, and safe products.

Cembre has received accreditation from CPD (Continued Professional Development) to offer certified training on their electrical crimping and compression connectors. Since CPD is a globally renowned independent accrediting body, you can take advantage of their knowledge and experience in the electrical connections industry while also earning CPD credits for your professional advancement.

The course aims to deliver ‘best practice’ crimping methods in accordance with BS7609; for electrical engineers; contractors; and installers. Delegates will learn the importance of material composition; cable preparation and using a ‘matched crimping system’.

▶ Thorne & Derrick provide competitive prices and fast delivery from stock for the complete range of Cembre cable lugs, connectors, cable cutting and cable crimping tools.

course Content

This training course covers the following:

• Connectors: what they are, how they work, and why they are important for reliable and safe LV MV HV electrical connections.
• BS7609 is the British standard that specifies the requirements and installation methods for un-insulated compression and mechanical connectors for power cables with copper or aluminium conductors.
• Matched system: the system that ensures the highest quality and safety of connections by using electrical connectors, crimping tools, and dies that are designed and tested together.

Participating in Cembre’s CPD-certified training courses offers many benefits, including:

1. Certified Excellence: The courses are meticulously crafted and assessed by CPD, ensuring alignment with the highest training standards and guidelines.
2. Flexible Learning: Whether you prefer face-to-face interaction or the convenience of online learning, our courses cater to diverse preferences and schedules.
3. Certification: Upon completing the training, you will receive a CPD training certificate that that acknowledges your participation and attendance.

Cable lugs are suitable for connection, termination and jointing of 11kV-33kV power cables with copper or aluminium conductors to MV-HV electrical equipment including switchgear, transformers and control panels

Cembre CPD TRAINING cOURSES

CEMBRE training courses are suitable for anyone who works with electrical connections, such as electricians, cable jointers, engineers, technicians, contractors, and inspectors. They are also flexible and convenient, as they can be arranged with local sales engineer at a time and place that suits you.

Contact Thorne & Derrick today to discuss your requirements.

Cembre is a leading European manufacturer of electrical connectors, crimping tools, cutting tools and a variety of accessories for LV (Low Voltage), MV (Medium Voltage) and HV (High Voltage) power systems. Designed for switchgear and control panels, Cembre tools are ideal for installing low and medium voltage connectors.

Key Product Categories: Duct Seals | Cable Cleats | Cable Glands | Electrical Safety | Arc Flash Protection | Cable Jointing Tools | Cable Pulling | Earthing | Feeder Pillars | Cable Joints LV | Joints & Terminations MV HV | Cold Shrink

T&D are Specialist Distributors of LV MV HV Cable Installation, Jointing, Substation & Electrical Equipment – we supply companies in the onshore and offshore wind, solar, rail, oil/gas, data centre, battery storage and utility sectors with products to enable the energisation, operation and maintenance of underground cables and overhead lines.

Reducing RSI Caused by Cable Crimping Using Ratchet Type Tools

manual ratchet Crimping tools

Reducing RSI In Cable Crimping Applications

Many cable crimping applications throughout the industry are conducted using manual ratchet tools or hand hydraulic tools. Depending on the number of operations conducted each day and the hand force required to close the handles of the crimping tool, Repetitive Strain Injury (RSI) can result.

➡ Thorne & Derrick, are leading suppliers of cable crimp lugs and associated crimping tools for Low, Medium & High Voltage Cables and Power Systems.

The average force required to close the handles of a ratchet crimp tool is 22kg, and with many applications in factories and OEM’s requiring 250+ terminations per day, a significant risk is exposed.

Employee health – Less physical effort due to electrically-driven tools

CABLE CRIMPING & HEALTH & SAFETY

Looking to statistics available on-line, 29% of repetitive strain injuries will result in Carpal Tunnel Syndrome (CTS). This condition is where the Median nerve in the wrist is squashed in the Carpal tunnel, creating chronic pain, pins and needles, and numbness in the fingers and hand of the operator.

In worst cases CTS can only be resolved with surgery, one hand at a time, resulting in employees being unable to work for 6-8 weeks.

Those at risk of CTS are employees where they have a combination of:-

1. Repetitive bending and stretching of the hand

2. High force applications of squeezing or gripping cable cutting or crimping tools

3. Exposure to high vibration (e.g. motor driven saws/ grinders)

Electromechanical Cable Crimping Tools

The new alternative to manual ratchet crimping tools for high volume, high force applications, is the Klauke Micro tool. This is an electro-mechanical tool suitable for Pre-insulated connectors (up to 16sqmm), Boot-lace ferrules (up to 50sqmm), and Cu tube lugs (up to 25sqmm). The Micro provides a 90% reduction in hand load experienced by the operator to help keep employees safe and maintain high productivity.

Electromechanical Crimping Tool Operation

Choosing the correct electromechanical crimping tools can help reduce workplace injuries and improve site and worker Health & Safety.

The Micro is less than 1kg, completes in excess of 300 crimps per charge in less than 1.5 secs per crimp. As an intelligent tool, it ensures full closure of the jaws on every crimp and comes with the ability to link to Klauke iPress software, where quality records can be downloaded and stored for improved traceability.

Klauke EK 50 ML 0.14sqmm – 50sqmm Electromechanical Crimping Tool

There are more reported cases of CTS in our industry and with better, safer, more productive tool solutions available today, each employer has a duty of care to provide the most suitable tools to their employees.

Electrical Connections, Lugs & Tools for Crimping, Cutting & Punching | LV MV HV Cables

Insulated Cable Cutters

The Klauke ES32SISML-WSH is a battery powered cable cutting tool with a maximum cutting range of 32mm suitable for use with copper and aluminium conductors up to 300sqmm. The Klauke ES32SISML insulated cable cutter has a slim cutting head for Jointers working in substations, switchgear and trenches with confined spaces – this insulated tool provides advanced worker and electrical protection to utility contractors working live in the vicinity of energised Mains and Service cables up to 1000V.

The insulated tool is typically used by UK DNO’s and their ICP Contractors to core cut 185sqmm, 240sqmm and 300sqmm BS7870 Waveform 600/1000V cables.

Klauke cutting tools are available with 10.8V DeWalt Li-Ion Batteries and are fully insulated to the electrical requirements of IEC 60900.

Cable Innovation Tools & Accessories for Low & High Voltage Power Systems

THORNE & DERRICK are Specialist Distributors of LV HV Cable Jointing, Earthing, Substation & Electrical Eqpt up to 66kV – this includes the most extensive range of Ex Stock Innovation Tooling to facilitate safe and reliable preparation, termination and installation of cables.

MV HV High Voltage Cable Joints | Cable Terminations | Cable Connectors | Distributed from Stock | UK & Export Sales

Story Time | The History of Klauke

Klauke Crimping & Cutting Tools

Do you know the history of Klauke?

Klauke is a leading manufacturer of cable crimping and cable cutting tools, the company has been in business for over 140 years.

It all began in 1879, when Gustav Klauke and his brother founded the company Gustav Klauke. At that time, the production program included high-quality pliers, primarily in the watchmaker trade.

In 1924, the founder’s sons, Gustav Klauke II and Max Klauke, took over the management of the company.

In 1960, the decision was made to produce cable lugs and corresponding tools. Klauke began to focus on developing tools for the electrical industry. They pioneered the development of manual crimping and cutting tools, which quickly gained popularity due to their high quality and reliability.

The Present Day

Did you also know that the first battery-powered hydraulic tool for connecting material was manufactured in 1994?

In 2014, the Klauke Micro with PowerSense function appeared on the market.

In July 2018, the company was acquired by Emerson and is now part of the “Professional Tools” division. Klauke celebrated its 140th anniversary the following year.

Over the years, Klauke expanded its product range to include hydraulic and battery-powered crimping and cutting tools to meet the growing demand in various industries such as electrical installations, air conditioning and refrigeration, automotive, and telecommunications.

Klauke prides itself on its innovative designs and commitment to manufacturing tools that meet the highest standards of quality and precision. Their tools are designed to be ergonomic, durable, and easy to use, ensuring optimal performance and efficiency.

Let’s take a closer look at their history below:

1924 – 1879

In 1924, the founder’s sons, Gustav Klauke II and Max Klauke, took over the management of the company

1924

The sons of the founder, Gustav Klauke II and Max Klauke, take over the management. The pliers product range is continued.

1912

Hand-forged pilers have been dropped and replaced by forged pliers. Mass production has begun. The company has approx. 60 employees.

1906

The Gustav Klauke company is entered in the Commercial Register as a “General Trading Company”. The factory space covers 1,200 m2.

1879

In 1879, 24-year old Gustav Klauke and his brother found the Gustav Klauke company in Stephanstrasse in the Osterbusch area of Remscheid, Germany with 5 employees. At the time, the product range comprises high-quality pliers, which find a ready market, primarily in the watchmaker trade, due to clean hand forging.

1959 – 1925

1925, the first English language catalogue for the piler range was created

1948

Following the death of Gustav Klauke II, in keeping with old traditions, the company is managed by his son-in-law Gustav Diederichs together with Max Klauke, and is converted into a limited liability company.

1930

The sales market is expanded by translating the catalogues into French and Spanish.

1925

The first English language catalogue for the pliers range appears. From the outset, Klauke goes for high-quality tools for the international markets too.

1979 – 1960

1979 Klauke celebrates 100 years of business

1979

Gustav Klauke GmbH celebrates its centenary in Remscheid.

1978

Karl-Gustav Diederichs becomes sole Managing Director and oversees 85 employees.

1968

The production of traditional pliers is ceased. At the same time, the production of cable lugs and crimping tools is extended.

1965

Gustav Diederichs’ son, Karl-Gustav Diederichs joins the company. There are now 45 employees.

1960

Increasing electrification gives the impetus to the decision to produce cable lugs and corresponding tools.

1990 – 1980

Between 1980-1990 increased their office space and number of employees

1990

To keep up with the steady growth, an adjacent 3,000 m2 piece of land is purchased. Thanks to an existing hall, a further 2,000 m2 production area is added. Klauke now has approx. 160 employees.

1988

The entire company moves into the new premises in Remscheid-Ueberfeld. The production and storage facilities now cover some 9,000 m².

1984

Production in the new halls is started on an area of over 4,000 m2 .

1980

Covering an area of 6,000 m2 , the original premises on Stephanstrasse are too small for continued company growth. In the Remscheid-Überfeld industrial area, land measuring about 17,000 m2 is acquired for the construction of new production, storage and office space.

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1995 – 1991

1994 the first battery-powered hydrau;ic tool for connectig material is manufactured.

1995

Klauke attains ISO 9001 certification for the first time.

1994

The first battery-powered hydraulic tool for connecting material is manufactured. The development and distribution of special products for the sanitary and heating industry starts – accompanied by the first catalogue for this field of application.

1993

Klauke Austria is established in Vienna. In the same year, INDIS, headquartered in Creutzwald, is integrated into the Klauke Group as Klauke France. At the same time, Dr Peters is bought out by Klauke. It produced connecting material and tools.

1991

Following the reunification of Germany, Gustav Klauke GmbH acquires HAW in Saxony, the current Bernsdorf branch covering a total area of 10,000 m².

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1999 – 1996

In 1998 Klauke expansion of distribution activities through TEXTRON’s Singapore office

1999

Karl Gustav Diederichs retires. A new product platform for hand-operated and battery-powered hydraulic crimping tools with 6 and 12 tonnes of crimping force is introduced. SAP R/3 is introduced at the Klauke headquarters in Remscheid.

1998

Expansion of distribution activities through TEXTRON’s Singapore office.

1997

Klauke starts marketing Greenlee cable pulling equipment in Europe. Hole-making, punching and cutting tools, as well as cable-pulling products are offered.

1996

Klauke is integrated into Textron , the American multi-industry group of companies. This gives the worldwide presence of Klauke and Greenlee products significant impetus. A new building with a further 5,000 m² of production and office spaces emerges on the neighbouring plot in Remscheid-Ueberfeld acquired in 1990.

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2006 – 2000

In 2001, Klauke UK, the sales office for Great Britain and Ireland opened.

2006

Klauke supports the “Electric Brands. Strong Partners” initiative for increasing brand awareness and becomes a member of “E-CHECK”, the test seal for electrical installations and devices. Klauke complements the existing product range with professional tools for commercial and industrial use.

2005

Greenlee products from the testing, measuring and inspection device range are introduced and distributed through Klauke.

2004

The Klauke Group celebrates 125 years in existence in Remscheid with a big party. The Klauke Service Mobile for on-site operations at customer premises is introduced. The vehicle fleet is continuously expanded over the next few years. The activities of Tempo Europe Limited are fully integrated into Klauke.

2003

The newly defined “Klauke Production Principle” is put into practice under LEAN and KAIZEN perspectives. The cooperation with “Voltimum”, the central Internet portal for all information concerning modern electronic installation technology begins.

2002

The Klauke mini, an innovative, light and easy-to-use tool, is produced on a new hydraulic tool platform and introduced onto the market. Together with the geographical expansion, sales of the international plumbing business increases noticeably.

2001

Klauke UK, the sales office for Great Britain and Ireland is opened.

2000

The Klauke multi, the universal tool patented worldwide for crimping, cutting and hole-making is launched onto the market. Expansion of distribution activities through the TEXTRON office in Shanghai.

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2012 – 2007

2009 Safety Plus Generation of battery-powered hydrauic crimping, cutting and universal tools are launched on the market

2012

The distribution office in Bangalore (India) is expanded to industrial premises with assembly capacity, Service Centre and warehouse. Development of activities according to the Lean Management Concept for Marketing/Sales and Administration. The innovative “blue connection” system for the standardised crimping of compacted, multi-stranded conductors according to VDE 0295 Class 2 is introduced onto the market.

2010

Klauke receives the FACHMETALL QM Context Award. This is in recognition of the continuously high quality of tested materials.

2009

The battery-powered hydraulic crimping, cutting and universal tools of the Safety Plus Generation are launched on the market. Klauke is certified for the first time according to ISO/TS 16949 (quality management system of the automotive industry) and ISO 14001 (environmental management system).

2008

The Klauke India sales office is opened in Bangalore. Utilux Europe, with sites in Slovakia and Great Britain, is bought out and integrated into the Klauke Group.

2007

The distribution company Klauke Russia is established in Moscow. A new central logistics centre is put into operation in Remscheid.

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2016 – 2013

In 2014 Klauke Micro, the world’s first electromechanical crimping tool with PowerSense technology is launched on the market

2016

Internet of Things and Industry 4.0 are trends that Klauke has already taken up with the next generation and is thus setting new standards. The new battery-powered hydraulic tools have a Bluetooth interface for mobile data read-out and tool configuration. Klauke Bernsdorf has been producing high-quality tools for 25 years.

2015

Klauke launches sale of HDE products in EMEA and India. Introduction of the new Klauke mini for the electrical and plumbing trades. The Klauke Ideas Management Scheme celebrates its tenth anniversary and receives an award from the German Institute for Ideas and Innovation Management. Klauke supports the “Ecurie Aix” team from RWTH Aachen University by providing tools and cable lugs.

2014

The Klauke micro, the world’s first electromechanical crimping tool with PowerSense technology is launched on the market. The distribution company Klauke Polska is opened close to Warsaw. Our distribution company Klauke France has been active in the market for 25 years. Gustav Klauke GmbH receives the Bergische Training Award 2014 in the category Of Companies with more than 250 employees.

2013

Klauke Slovakia and Klauke UK introduce SAP. All Klauke companies in Europe are now migrated to SAP. Klauke Iberia, the distribution company for Spain and Portugal is opened in Madrid. Klauke opens a new production facility in China close to the city of Nantong. Greenlee celebrates its 150th anniversary. Klauke Germany and Klauke Slovakia receive an award for occupational safety to commend the low accident rate in recent years.

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2019 – 2017

In 2019, Klauke celebrates 140th anniversary

2019

Klauke Remscheid celebrates its 140th anniversary. Unique in the world: In April, the battery-powered hydraulic cutting and crimping tools will be Klauke Orange are presented. These offer protection against electric shock up to 1,000 V.

2018

In May 2018, Klauke India celebrates its 10th anniversary and also moves to new premises. Mid-2018 Klauke Austria also celebrates its 25th anniversary. In July 2018, Gustav Klauke GmbH is acquired by Emerson and is now part of the “Professional Tools” division.

2017

On 4 May 2017, the ceremonial opening of our new production site in Gelnica/Slovakia takes place, so that production is now extended to another location in Slovakia with about 2,000 m². Klauke also opens another hall in the “Auf dem Knapp” industrial estate to expand the logistics area. Klauke Spain moves to its new facilities in Madrid.

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2020 – 2023

2023 – Two new Managing Directors of Gustav Klauke GmbH

2023

Marc Vandevelde and Jean-Claude Wetzels become joint Managing Directors of Gustav Klauke GmbH.

2020

Timothy Reeves becomes Managing Director and a one piece flow assembly line is introduced for production at Remscheid. The aim is to achieve faster production, better delivery performance and even higher levels of quality.

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Today, Klauke products are used by professionals around the world. Their extensive range includes a wide variety of crimping tools for different applications, such as cable lugs, connectors, and terminals. They also offer cutting tools for cables, pipes, and other materials.

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CRIMPING CABLES, LUGS & TOOLS

Thorne & Derrick distribute Cable Lugs & Cable Connectors to terminate, splice and joint LV MV HV cables – this includes copper, aluminium and bi-metallic connectors and a complete range of crimping tools for specific use on all Low, Medium & High Voltage cable types.

➡ Associated Brands & Products | Klauke | Cembre | Pfisterer Sicon | Cable Crimping & Cable Cutting Tools

Klauke Remote Bluetooth Cutting Tools with Network Rail Approvals (PADS)

Klauke Remote Bluetooth Cutting Tools

Network Rail Approvals (PADS) Overhead Line Cutting Tools

This unique overhead line cutting tool by Klauke allows the user to operate and control the cutting function remotely via Bluetooth technology. Ideal for cutting applications at height where there are potential benefits from carrying out this work from ground level.

Cable cutting and crimping tools manufactured by Klauke are renowned for high-quality, electrical connection tools for cable crimping, cutting and punching – special cable tooling solutions for applications in a range of different sectors.

The Klauke tool is fully trialled and approved for use within Network Rail, PADS Acceptance Certificate No: PA05/06827.

When used in conjunction with telescopic or sectional operating poles the user is easily able to manoeuvre the cutter into a convenient position to enable the cutting of jumpers, conductor tail ends, vegetation and debris on or in the vicinity of power lines.

The overhead line cutting tools is available in 3 versions for cutting ACSR conductor (20mm dia max), copper and aluminium conductor (32mm dia.) or vegetation such as small tree branches up to 50mm diameter.

The cutting tool from Klauke is operated via the BTC2 remote fob which has a simple 2-function button. Available on Makita or Bosch battery platforms. All cutting tools can be operated as hand tools by removing the yellow attachment collar and switching from remote to manual operation via the Led display.

Klauke Remote Bluetooth Cutting Tool | Please contact us if you would to book a demonstration.

Cutting Tool Features

• Operation can be switched between manual / remote operation using LED Display
• One-button operating concept for controlling all functions
• Balanced centre of gravity for easy handling and effortless operations, especially when used with hotsticks, telescopic or sectional operating rods
• Quick motor stop for added user safety
• Automatic retraction when cutting operation is complete. Manual retraction when required
• Operated remotely using Bluetooth fob
• LED for workplace illumination
• Open head rotates through 300°
• LED display for tool data
• Yellow collar fitted with universal rose to allow all angle attachment of operating rod ensuring perfect positioning for cut

Ideal for Cable Cutting Applications at Height

Klauke Remote Bluetooth Cutting Tools

Technical Specifications

Klauke Remote Bluetooth Cutting ToolS

CRIMPING CABLES, LUGS & TOOLS

Thorne & Derrick distribute Cable Lugs & Cable Connectors to terminate, splice and joint LV MV HV cables – this includes copper, aluminium and bi-metallic connectors and a complete range of crimping tools for specific use on all Low, Medium & High Voltage cable types, including ratchet cable cutters.

➡ Associated Brands & Products | Klauke | Cembre | Pfisterer Sicon | Cable Crimping & Cable Cutting Tools

Compression Cable Lugs According To DIN 46235 By Klauke

DIN 46235

Compression Cable Lugs

DIN 46235 is a standard that defines the applications, dimensions and the designation of compression cable lugs. Compression cable lugs according to this standard may be used for one, several, fine and super-fine stranded conductors.

The conductor design is defined in DIN EN 60228 (IEC 60228). The conductor design was previously described in VDE 0295. Copper cables according to DIN 48201-1 can also be processed using these cable lugs.

▶ Thorne & Derrick International, based in the UK, are leading suppliers of cable crimp lugs and associated crimping tools for Low, Medium & High Voltage Cables and Power Systems – this series of articles by Klauke discusses the theory and practise of installing compression type cable lugs and connectors.

When processing sector conductors, attention must be paid to ensure that the sector conductors are pre-rounded using the corresponding tool. Pre-rounding dies with the right sector sleeves are suitable for this purpose, for example.

The markings on the product provide useful information about the origin and use of the compression cable lugs – the same also applies to tubular cable lugs. Here is an example of what “KL 20 12 – 120” means:

• KL: Manufacturer code (Klauke in this particular instance)
• 20: Tool number (only for cable lugs according to DIN 46235)
• 12: Size of standard metric bolt dimensions for the connecting bolts – in this case M 12 screws
• 120: Specified nominal cross-section of conductor in mm²

3 types of lugs: DIN cable lugs, standard tubular cable lugs and sheet metal terminals (from left to right)

Compression cable lugs also have markings that provide information regarding the number and width of crimpings. The standard recommends hexagonal crimping dies according to DIN 48083-4 for processing purposes. The hexagonal dimensions are described in this standard. This means you can be sure the connection is definitely DIN-compliant.

The conductor nominal cross-sections of compression cable lugs range from 6sqmm to 1000sqmm, the hole diameter for the connecting bolt is between M5 and M20.

Compression cable lugs are made from electrolyte copper: a copper tube is shaped into a cable lug by crimping and cutting. Compression cable lugs are tin plated as standard to protect against corrosion – just like tubular cable lugs and solderless terminals. However bright finish versions are available as well.

The associated compression joint is defined in DIN 46267-1. However, the properties and processing are identical.

Cable cutting and crimping tools manufactured by Klauke are renowned for high-quality, electrical connection tools for cable crimping, cutting and punching – special cable tooling solutions for applications in a range of different sectors.

CRIMPING CABLES, LUGS & TOOLS

Thorne & Derrick distribute Cable Lugs & Cable Connectors to terminate, splice and joint LV MV HV cables – this includes copper, aluminium and bi-metallic connectors and a complete range of crimping tools for specific use on all Low, Medium & High Voltage cable types.

➡ Associated Brands & Products | Klauke | Cembre | Pfisterer Sicon | Cable Crimping & Cable Cutting Tools