COPPER BUSBARS

Our extensive knowledge and experience in the production of copper Busbars, complemented by our state-of-the-art EHRT technology allows us to fully customise and create bespoke copper Busbars at the highest level of quality for clients in the power, rail, medical, marine, data centre, motor sport, and aerospace industries.

Copper is an incredibly versatile material. Recognised for its low thermal and electrical resistance, high strength in tension & compression, shear strength, and strong fatigue resistance properties, to name a few. Our copper Busbars are a key component of electrical utilities such as switchgear, panel boards, and busway enclosures. They can be used for local high current power distribution but also for any application that fits your specification.

Alternatives to Copper Busbars

Aluminium is the main alternative and has many positive attributes that will lend themselves to specific tasks and applications. An in-depth comparison of the properties of both metals clearly shows that in practically every respect, copper is the superior Busbar material.

Why Copper Makes a Superior Busbar

The efficient proportions of copper enable higher currents to be passed through the material. Copper bests aluminium in electrical ratings, when compared by volume, and has lower electrical resistance, lower power loss, lower voltage drop and higher ampacity. The larger overall dimensions of an aluminium Busbar system may not be ideal for certain situations such as in small buildings or underfloor, whereas copper designs can be sized for any application.

Copper is also resilient to high temperatures, providing added security protection in short circuit situations. Temperature changes that may occur in service settings need a degree of design flexibility. Copper has a higher tensile strength than aluminium, which makes it more resistant to harm during installation and use. Reliability is a key factor in the choice of materials and copper has the credentials to fulfil all these specific needs.

These contributing factors all affect the electrical efficiency of a Busbar trunking system. The only real disadvantage of copper is its higher density. Therefore it will require more manpower at the installation stage and must be in mind if a system has specific weight requirements. As energy is expensive, these considerations at the design stage of ILF’s Busbar service are measures taken to increase energy efficiency throughout your bespoke system. These systems will lead to, and ultimately prove to be more cost-effective. We can advise you on these choices every step of the way.

Overall, our copper Busbars provide you with the perfect balance of cost versus application.  Most importantly for projects where high performance, versatility and reliability are required, this product will stand the test of time.

What Is Busbar Trunking?

Busbar Trunking is a method of distributing electric power that employs copper or aluminium busbars with appropriate enclosures. It provides adequate protection for cables, preventing them from being damaged by foreign bodies. Trunking also significantly improves system cooling when compared to traditional cables.

Trunking systems significantly reduce installation and maintenance time due to a fast joining feature that allows you to put it together in no time. Trunking systems will also save money on installation and maintenance because there is no need for hardwiring.

Another advantage is that you can purchase individual busbars, which aids in cost calculation based on the number of copper busbars required.

What is a Tin Plated Busbar and where to use it?

The most adaptable finish for copper bus bars is tin plating. Under various climatic situations, tin offers excellent corrosion protection for components prone to tarnish. Power electronics parts with tin coating have great solderability.

Tin plating gives copper excellent solderability while providing a shiny look and corrosion resistance.

It’s best used in rigid connections with high power running through.

What is Electrolytic-tough Pitch Copper?

The most popular grade of copper used worldwide is electrolytic tough pitch copper, UNS C11000, which is pure copper purified by the electrolytic method with a maximum of 0.0355% impurities. ETP has an IACS conductivity value of at least 100%.

An elemental feature of a substance that measures how strongly it resists or conducts the flow of electric current is known as electrical resistivity, and its opposite is electrical conductivity. A substance that readily permits the flow of electric current has a low resistance. The Greek letter is frequently used as the symbol for resistivity (rho). The ohm-metre (m) is the SI unit of electrical resistivity. Keep in mind that electrical resistivity differs from electrical resistance. In Ohms, the electrical resistance is measured. Resistance is a characteristic of a thing, whereas resistivity is a feature of materials.

Benefits Overview:

  • Saves space when compared to aluminium
  • Industry standard material
  • Has many different plating options all with their own specific benefits
  • Multiple options for connectivity and configuration
  • Thermally and electrically efficient as well as Lower Insulation Resistance (IR) drop

Properties of Solid Copper Busbars:

Chemical Composition of Cu-ETP:

  • Cu – 99.90
  • Bi – Max 0.0005
  • Pb – Max 0.005
  • O – Max 0.040
  • Others 0.03

Tensile Strength: 250N/mm2

Resistivity: 0.0172Ωmm2/mm

Density: 8.9kh/dm3

Current Rating: 1 Sq.mm of copper can withstand 1.2 Amperes

Copper Busbar manufacturer and stockist of aluminium, copper, bronze and steel in the UK

Sample Copper Busbars can be produced on request

Our copper 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

Busbar Icon for UK Industry

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

Busbar Icon for UK Industry

Sleeving and coating including Polyolefin, UPVC and more.

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

FOR MORE INFORMATION TELEPHONE OUR SALES TEAM ON 01543 226816

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

Conductivity Rating Table:

Busbar SizeX Sectional areaWeightApprox D.C Resistance 20°CApprox D.C rating (1)Approx A.C ratingMoment of InertiaModulus of Section Z
Busbar SizeX Sectional areaWeightApprox D.C Resistance 20°CStill Air (3)Free Air (3)Still AirFree AirEdge-wiseFlatEdge-wiseFlat
mmmm2kg/mmW/mAAAAmm4mm4mm3mm3
10 x 1.60160.1431077105115105115133.33.41326.664.266
12.5 x 1.60200.179862125135125135260.44.26641.665.333
16 x 1.6025.60.229673155170155170546.15.46168.266.826
20 x 1.60320.2865381852051852051,0666.826106.68.533
25 x 1.60400.3574312252502252502,0838.533166.610.67
30 x 1.60480.4293592652902652903,60010.2424012.8
10 x 2.00200.179862115130115130166.66.66633.326.666
12.5 x 2.00250.223689140155140155325.58.33352.088.333
16 x 2.00320.286538175190175190682.610.6685.3310.66
20 x 2.00400.3574312102302102301,33313.33133.313.33
25 x 2.00500.4463442552802552802,60416.66208.316.66
30 x 2.00600.5362872953302953304,5002030020
40 x 2.00800.71421538042038042010,66026.6653326.66
10 x 2.50250.223689130145130145208.313.0241.6610.42
12.5 x 2.5031.252.279557160175160175406.916.2765.613.02
16 x 2.50400.357431195215195215853.320.83106.716.66
20 x 2.50500.4463442352602352601,66626.04166.620.83
25 x 2.5062.50.5582752853152853153,25532.55260.426.04
30 x 2.50750.672293303703303705,62539.0637531.25
40 x 2.501000.89317242547542547513,33052.08666.541.66
50 x 2.501251.11513752057552057526,04065.1104152.08
60 x 2.501501.33911460567560567545,00078.13150062.5
10 x 2.7531.50.281547150170150170262.526.05520516.54
12.5 x 2.7539.40.352437180200180200512.732.5682.0320.67
20 x 3.0600.5362872602902602902,0004520030
25 x 3.0750.672293153503143503,90656.25312.437.5
30 x 3.0900.8031913654053654056,75067.545045
40 x 3.01201.07114347052047052016,0009080060
50 x 3.01501.33911457063557063531,250112.51,25075
60 x 3.01801.60795.766574066574054,0001351,80090
80 x 3.02402.14271.8860955860955128 x 1031803,200120
10 x 4.0400.357431175195175195333.353.3366.6626.67
12.5 x 4.0500.44634421023021023065166.67104.233.34
16 x 4.0640.5712692552852552851,36585.33170.642.67
20 x 4.0800.7142153053403053402,666106.7266.653.35
25 x 4.01000.8931723654103654105,208133.3416.666.65
30 x 4.01201,0711434304754304758,9991600599.680
40 x 4.01601.42810754561054060521,330213.31,066.50106.7
50 x 4.02001.78586.266574066073541,660266.71,666133.4
60 x 4.02402.14271.877586077085572,0003202,400160
80 x 4.03202.85653.89951,1209801,105170 x 103426.74,268213.4
100 x 4.04003.57143.11,2101,3651,1851,340333 x 103533.36,666266.7
10 x 5.0500.446344200225200225416.7104.283.3441.68
12.5 x 5.062.50.558275240265240265813.4130.2130.152.08
16 x 5.0800.7142152903252903251,707166.7213.466.68
20 x 5.01000.8931723453853453853,333208333.383.2
25 x 5.01251.1161374154654154656,560260.4520.8104.2
30 x 5.01501.33911448554048054011,250312.5750125
40 x 5.02001.78586.261568561068026,670416.71334166.7
50 x 5.02502.23268.974583074082052,080520.82,083208.3
60 x 5.03002.67857.487097086596090,0006253,000250
80 x 5.040035714311,1201,2601,1101,250213 x 103833.35,333333.3
100 x 5.050044643441,3551,5301,3451,520417 x 1031,0428,334416.8
10 x 6.3630.562273235260235260525208.410566.16
12.5 x 6.378.750.7032182753052753051,025260.516482.7
16 x 6.3100.80.8991713353703353702,150333.4268.8105.8
20 x 6.01201.0711433854303854304,000360400120
25 x 6.01501.3391144605154605157,813450625150
30 x 6.01801.60795.753560053559515,500540900180
40 x 6.02402.14271.868076067575532,0007201,600240
50 x 6.03002.67857.482591581591062,5009002,500300
60 x 6.03603.21447.89651,0759551,065108 x 1031,0803,600360
80 x 6.04804.28535.91,2301,3701,2201,355256 x 1031,4406,400480
100 x 6.06005.35628.71,4901,6801,4801,670500 x 1031,80010,000600
120 x 6.07206.42823.91,7501,9701,7001,915864 x 1032,16014,400720
160 x 6.09608.5717.92,2502,5352,1302,4002.05 x 1062,88025,600960
20 x 8.01601.4281074605104555105,333853.3533213.3
25 x 8.02001.78586.254561054560510,4201,067833.6266.7
30 x 8.02402.14271.863070563070018,0001,2801,200320
40 x 8.03202.85653.880089079588542,6701,7072,134426.8
50 x 8.04003.57143.19651,0709501,05583,3002,1333,333533.3
60 x 8.04804.28535.91,1201,2501,1101,235144 x 1032,5604,800640
80 x 8.06405.71326.91,4351,5951,4201,580341 x 1033,4138,533853.3
100 x 8.08007.14221.51,7351,9551,5951,800667 x 1034,26713,3301067
120 x 8.09608.5717.92,0322,2901,7601,9851.15 x 1065,12019,2001280
160 x 8.0128011.4313.42,6102,9352,2302,5102.73 x 1066,82734,1401707
200 x 8.0160014.2710.83,1703,5702,7603,1105.33 x 1068,53353,3302133
20 x 102001.78586.25255854805356,6701,667667333.4
25 x 102502.23268.962569558064513,0202,0831,042416.6
30 x 103002.67857.472082570079522,5002,5001,500500
40 x 104003.57143.19101,03088099553,3303,3332,667666.6
50 x 105004.6434.41,0901,2351,0601,200104 x 1034,1674,168833.4
60 x 106005.35628.71,2701,4351,2001,355180 x 1035,0006,0001,000
80 x 108007.14221.51,6151,8401,5251,735427 x 1036,66710,6701,333
100 x 101,0008.92817.21,9502,2251,8002,065833 x 1038,33316,6701,667
120 x 101,20010.7114.32,2852,6102,1002,395144 x 10310,00023,9802,000
160 x 101,60014.2810.72,9303,3802,6203,040341 x 10313,33042,6602,666
200 x 102,0017.848.623,5504,1503,1403,6306.67 x 10616,67066,6703,334
250 x 102,50022.36.894,3205,0303,7104,31013.0 x 10620,830104 x 1034,166
25 x 123002.67857.470071064065015,6303,5991,250599.8
30 x 123603.21447.880582075076527,0004,3191,800719.8
40 x 124804.28535.91,0101,1009501,03064,0005,7593,200959.8
50 x 126005.35628.71,2101,3301,1601,275125 x 1037,1995,0001,199
60 x 127206.42823.91,4051,5501,3201,455216 x 1038,6397,2001,439
80 x 129608.5717.91,7852,0001,6701,870512 x 10311,51912,8001,919
100 x 121,20010.7114.32,1552,4202,0102,2551.00 x 10614,39020,0002,398
120 x 121,44012.8511.92,5202,8802,3102,6401.73 x 10617,28028,8002,880
160 x 121,92017.148.973,2253,6502,8603,2354.10 x 10623,04051,2003,840
200 x 122,40021.437.183,9104,4803,3803,8708.00 x 10628,79080,0004,798
250 x 123,00026.785.744,7505,4404,0604,65015.6 x 10635,990125 x 1035,998
25 x 164003.57143.184096074085520,8308,53316.7 x 1031,067
30 x 164804.28535.99601,09584597535,99010,24024.0 x 1031,280
40 x 166405.71326.91,2001,3701,0551,22085,33013,65042.7 x 1031,706
50 x 168007.14221.51,4301,6351,2601,450167 x 10317,07066.7 x 1032,134
60 x 169608.5717.91,6601,8951,4601,685288 x 10320,48096.0 x 1032,560
80 x 161,28011.4313.42,1002,4001,8502,130683 x 10327,310171 x 1033,414
100 x 161,60014.2810.72,5302,8802,2202,5601.33 x 10634,130267 x 1034,266
120 x 161,92017.148.972,9403,3602,5902,9902.30 x 10640,960384 x 1035,120
160 x 162,56022.856.733,7504,3603,1803,7005.46 x 10654,610683 x 1036,826
200 x 163,20028.575.384,5405,7253,7604,37010.7 x 10668,2701.07 x 1068,534
250 x 164,00035.714.315,5206,4254,5005,25020.8 x 10685,3301.67 x 10610,670
300 x 164,80042.843.596,4607,5255,2706,15036.0 x 106102 x 1032.40 x 10612,800