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Our 30 years of experience in the production of Busbars and bus systems, combined with the use of state-of-the-art EHRT technology allows us to produce the finest quality, customised aluminium Busbars for clients in the power, rail, medical, marine, data centre, motor sport and aerospace industries.

Aluminium Busbars can be useful for multiple applications such as in transformers, distribution boards and electrical panel boards. Compared to copper, aluminium Busbars are made from a lighter material and are therefore more cost-effective to mass produce.

This material offers a complete solution for companies where budget, maximum weight and ease of installation are the key considerations.

Aluminium VS Copper Busbars

Compared to copper, aluminium has the potential to be up to 70% lighter, however, an aluminium Busbar system must be significantly larger in surface area than a copper one because it only has 62% the conductivity of copper. This lesser conductivity means that the size of conductor must be larger to match the current carrying capacity of a copper unit.

By volume copper is superior to aluminium, with regards to electrical ratings, but when compared by weight, aluminium is more electrically efficient. This is because aluminium has a density that is 70% lower than copper which makes it the more viable option when Busbar size is not problematic.

Lighter aluminium conductors lead to cost saving advantages with fewer supports required to properly secure the unit, quicker installation times and a drastic reduction in the cost of transportation. Supporting this argument when it comes to price, copper is the more volatile of the two materials for several consumer and economic factors. In 2020, the London Metal Exchange reported that the price ratio of copper to aluminium was around 3:1.

Therefore, aluminium provides companies and contractors the opportunity to assemble costing forecasts more accurately and this has meant that Busbar manufacturers such as ILF have been able to consistently pass on significant savings to our clients worldwide.

Metal and the Environment

From an environmental standpoint, aluminium and copper are both 100% recyclable but there are differences in their sustainability. 75% of the aluminium ever created is still in use today compared to 65% of copper. As it is less reliant on mining and unsustainable processes of extraction like copper, aluminium is by far the more sustainable option for Busbar trunking conductors.

If the size of the installation is not a factor in your project specification but weight limitations are a concern, this alloy could be the material that will save you costs without compromising conductivity.

Additional benefits of aluminium busbars may include:

  • Minimal price fluctuation as supply is not linked to the volatile commodity market
  • Custom designed aluminium profiles can allow for a larger surface area which offers greater heat exchange and more efficient thermal dissipation
  • Less manpower is required as lightweight components mean easier installation

Our aluminium Busbar manufacture can include:

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Busbars from 15mm to 200mm wide

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Busbars from 3mm to 16mm thick

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40 ton punching

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Bending accuracy of +/-0.1 degrees

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Plating in tin, nickel, precious and semi-precious metals

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Sleeving and coating including Polyolefin, UPVC and more.

An invaluable link in your supply chain delivering quality products on time, every time


Offering quality and precision as standard in busbar and metal component supply