COPPER BUSBARS

Stocking a comprehensive range of copper bars allows us to fulfill any order requirement quickly

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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

Sample Copper Busbars can be produced on request

Our copper Busbar manufacture can include:

Busbars from 15mm to 200mm wide

Busbars from 3mm to 16mm thick

40 ton punching

Bending accuracy of +/-0.1 degrees

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

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 Size	X Sectional area	Weight	Approx D.C Resistance 20°C	Approx D.C rating (1)		Approx A.C rating		Moment of Inertia		Modulus of Section Z
Busbar Size	X Sectional area	Weight	Approx D.C Resistance 20°C	Still Air (3)	Free Air (3)	Still Air	Free Air	Edge-wise	Flat	Edge-wise	Flat
mm	mm2	kg/m	mW/m	A	A	A	A	mm4	mm4	mm3	mm3
10 x 1.60	16	0.143	1077	105	115	105	115	133.3	3.413	26.66	4.266
12.5 x 1.60	20	0.179	862	125	135	125	135	260.4	4.266	41.66	5.333
16 x 1.60	25.6	0.229	673	155	170	155	170	546.1	5.461	68.26	6.826
20 x 1.60	32	0.286	538	185	205	185	205	1,066	6.826	106.6	8.533
25 x 1.60	40	0.357	431	225	250	225	250	2,083	8.533	166.6	10.67
30 x 1.60	48	0.429	359	265	290	265	290	3,600	10.24	240	12.8
10 x 2.00	20	0.179	862	115	130	115	130	166.6	6.666	33.32	6.666
12.5 x 2.00	25	0.223	689	140	155	140	155	325.5	8.333	52.08	8.333
16 x 2.00	32	0.286	538	175	190	175	190	682.6	10.66	85.33	10.66
20 x 2.00	40	0.357	431	210	230	210	230	1,333	13.33	133.3	13.33
25 x 2.00	50	0.446	344	255	280	255	280	2,604	16.66	208.3	16.66
30 x 2.00	60	0.536	287	295	330	295	330	4,500	20	300	20
40 x 2.00	80	0.714	215	380	420	380	420	10,660	26.66	533	26.66
10 x 2.50	25	0.223	689	130	145	130	145	208.3	13.02	41.66	10.42
12.5 x 2.50	31.25	2.279	557	160	175	160	175	406.9	16.27	65.6	13.02
16 x 2.50	40	0.357	431	195	215	195	215	853.3	20.83	106.7	16.66
20 x 2.50	50	0.446	344	235	260	235	260	1,666	26.04	166.6	20.83
25 x 2.50	62.5	0.558	275	285	315	285	315	3,255	32.55	260.4	26.04
30 x 2.50	75	0.67	229	330	370	330	370	5,625	39.06	375	31.25
40 x 2.50	100	0.893	172	425	475	425	475	13,330	52.08	666.5	41.66
50 x 2.50	125	1.115	137	520	575	520	575	26,040	65.1	1041	52.08
60 x 2.50	150	1.339	114	605	675	605	675	45,000	78.13	1500	62.5
10 x 2.75	31.5	0.281	547	150	170	150	170	262.5	26.05	5205	16.54
12.5 x 2.75	39.4	0.352	437	180	200	180	200	512.7	32.56	82.03	20.67
20 x 3.0	60	0.536	287	260	290	260	290	2,000	45	200	30
25 x 3.0	75	0.67	229	315	350	314	350	3,906	56.25	312.4	37.5
30 x 3.0	90	0.803	191	365	405	365	405	6,750	67.5	450	45
40 x 3.0	120	1.071	143	470	520	470	520	16,000	90	800	60
50 x 3.0	150	1.339	114	570	635	570	635	31,250	112.5	1,250	75
60 x 3.0	180	1.607	95.7	665	740	665	740	54,000	135	1,800	90
80 x 3.0	240	2.142	71.8	860	955	860	955	128 x 103	180	3,200	120
10 x 4.0	40	0.357	431	175	195	175	195	333.3	53.33	66.66	26.67
12.5 x 4.0	50	0.446	344	210	230	210	230	651	66.67	104.2	33.34
16 x 4.0	64	0.571	269	255	285	255	285	1,365	85.33	170.6	42.67
20 x 4.0	80	0.714	215	305	340	305	340	2,666	106.7	266.6	53.35
25 x 4.0	100	0.893	172	365	410	365	410	5,208	133.3	416.6	66.65
30 x 4.0	120	1,071	143	430	475	430	475	8,999	1600	599.6	80
40 x 4.0	160	1.428	107	545	610	540	605	21,330	213.3	1,066.50	106.7
50 x 4.0	200	1.785	86.2	665	740	660	735	41,660	266.7	1,666	133.4
60 x 4.0	240	2.142	71.8	775	860	770	855	72,000	320	2,400	160
80 x 4.0	320	2.856	53.8	995	1,120	980	1,105	170 x 103	426.7	4,268	213.4
100 x 4.0	400	3.571	43.1	1,210	1,365	1,185	1,340	333 x 103	533.3	6,666	266.7
10 x 5.0	50	0.446	344	200	225	200	225	416.7	104.2	83.34	41.68
12.5 x 5.0	62.5	0.558	275	240	265	240	265	813.4	130.2	130.1	52.08
16 x 5.0	80	0.714	215	290	325	290	325	1,707	166.7	213.4	66.68
20 x 5.0	100	0.893	172	345	385	345	385	3,333	208	333.3	83.2
25 x 5.0	125	1.116	137	415	465	415	465	6,560	260.4	520.8	104.2
30 x 5.0	150	1.339	114	485	540	480	540	11,250	312.5	750	125
40 x 5.0	200	1.785	86.2	615	685	610	680	26,670	416.7	1334	166.7
50 x 5.0	250	2.232	68.9	745	830	740	820	52,080	520.8	2,083	208.3
60 x 5.0	300	2.678	57.4	870	970	865	960	90,000	625	3,000	250
80 x 5.0	400	3571	431	1,120	1,260	1,110	1,250	213 x 103	833.3	5,333	333.3
100 x 5.0	500	4464	344	1,355	1,530	1,345	1,520	417 x 103	1,042	8,334	416.8
10 x 6.3	63	0.562	273	235	260	235	260	525	208.4	105	66.16
12.5 x 6.3	78.75	0.703	218	275	305	275	305	1,025	260.5	164	82.7
16 x 6.3	100.8	0.899	171	335	370	335	370	2,150	333.4	268.8	105.8
20 x 6.0	120	1.071	143	385	430	385	430	4,000	360	400	120
25 x 6.0	150	1.339	114	460	515	460	515	7,813	450	625	150
30 x 6.0	180	1.607	95.7	535	600	535	595	15,500	540	900	180
40 x 6.0	240	2.142	71.8	680	760	675	755	32,000	720	1,600	240
50 x 6.0	300	2.678	57.4	825	915	815	910	62,500	900	2,500	300
60 x 6.0	360	3.214	47.8	965	1,075	955	1,065	108 x 103	1,080	3,600	360
80 x 6.0	480	4.285	35.9	1,230	1,370	1,220	1,355	256 x 103	1,440	6,400	480
100 x 6.0	600	5.356	28.7	1,490	1,680	1,480	1,670	500 x 103	1,800	10,000	600
120 x 6.0	720	6.428	23.9	1,750	1,970	1,700	1,915	864 x 103	2,160	14,400	720
160 x 6.0	960	8.57	17.9	2,250	2,535	2,130	2,400	2.05 x 106	2,880	25,600	960
20 x 8.0	160	1.428	107	460	510	455	510	5,333	853.3	533	213.3
25 x 8.0	200	1.785	86.2	545	610	545	605	10,420	1,067	833.6	266.7
30 x 8.0	240	2.142	71.8	630	705	630	700	18,000	1,280	1,200	320
40 x 8.0	320	2.856	53.8	800	890	795	885	42,670	1,707	2,134	426.8
50 x 8.0	400	3.571	43.1	965	1,070	950	1,055	83,300	2,133	3,333	533.3
60 x 8.0	480	4.285	35.9	1,120	1,250	1,110	1,235	144 x 103	2,560	4,800	640
80 x 8.0	640	5.713	26.9	1,435	1,595	1,420	1,580	341 x 103	3,413	8,533	853.3
100 x 8.0	800	7.142	21.5	1,735	1,955	1,595	1,800	667 x 103	4,267	13,330	1067
120 x 8.0	960	8.57	17.9	2,032	2,290	1,760	1,985	1.15 x 106	5,120	19,200	1280
160 x 8.0	1280	11.43	13.4	2,610	2,935	2,230	2,510	2.73 x 106	6,827	34,140	1707
200 x 8.0	1600	14.27	10.8	3,170	3,570	2,760	3,110	5.33 x 106	8,533	53,330	2133
20 x 10	200	1.785	86.2	525	585	480	535	6,670	1,667	667	333.4
25 x 10	250	2.232	68.9	625	695	580	645	13,020	2,083	1,042	416.6
30 x 10	300	2.678	57.4	720	825	700	795	22,500	2,500	1,500	500
40 x 10	400	3.571	43.1	910	1,030	880	995	53,330	3,333	2,667	666.6
50 x 10	500	4.64	34.4	1,090	1,235	1,060	1,200	104 x 103	4,167	4,168	833.4
60 x 10	600	5.356	28.7	1,270	1,435	1,200	1,355	180 x 103	5,000	6,000	1,000
80 x 10	800	7.142	21.5	1,615	1,840	1,525	1,735	427 x 103	6,667	10,670	1,333
100 x 10	1,000	8.928	17.2	1,950	2,225	1,800	2,065	833 x 103	8,333	16,670	1,667
120 x 10	1,200	10.71	14.3	2,285	2,610	2,100	2,395	144 x 103	10,000	23,980	2,000
160 x 10	1,600	14.28	10.7	2,930	3,380	2,620	3,040	341 x 103	13,330	42,660	2,666
200 x 10	2,00	17.84	8.62	3,550	4,150	3,140	3,630	6.67 x 106	16,670	66,670	3,334
250 x 10	2,500	22.3	6.89	4,320	5,030	3,710	4,310	13.0 x 106	20,830	104 x 103	4,166
25 x 12	300	2.678	57.4	700	710	640	650	15,630	3,599	1,250	599.8
30 x 12	360	3.214	47.8	805	820	750	765	27,000	4,319	1,800	719.8
40 x 12	480	4.285	35.9	1,010	1,100	950	1,030	64,000	5,759	3,200	959.8
50 x 12	600	5.356	28.7	1,210	1,330	1,160	1,275	125 x 103	7,199	5,000	1,199
60 x 12	720	6.428	23.9	1,405	1,550	1,320	1,455	216 x 103	8,639	7,200	1,439
80 x 12	960	8.57	17.9	1,785	2,000	1,670	1,870	512 x 103	11,519	12,800	1,919
100 x 12	1,200	10.71	14.3	2,155	2,420	2,010	2,255	1.00 x 106	14,390	20,000	2,398
120 x 12	1,440	12.85	11.9	2,520	2,880	2,310	2,640	1.73 x 106	17,280	28,800	2,880
160 x 12	1,920	17.14	8.97	3,225	3,650	2,860	3,235	4.10 x 106	23,040	51,200	3,840
200 x 12	2,400	21.43	7.18	3,910	4,480	3,380	3,870	8.00 x 106	28,790	80,000	4,798
250 x 12	3,000	26.78	5.74	4,750	5,440	4,060	4,650	15.6 x 106	35,990	125 x 103	5,998
25 x 16	400	3.571	43.1	840	960	740	855	20,830	8,533	16.7 x 103	1,067
30 x 16	480	4.285	35.9	960	1,095	845	975	35,990	10,240	24.0 x 103	1,280
40 x 16	640	5.713	26.9	1,200	1,370	1,055	1,220	85,330	13,650	42.7 x 103	1,706
50 x 16	800	7.142	21.5	1,430	1,635	1,260	1,450	167 x 103	17,070	66.7 x 103	2,134
60 x 16	960	8.57	17.9	1,660	1,895	1,460	1,685	288 x 103	20,480	96.0 x 103	2,560
80 x 16	1,280	11.43	13.4	2,100	2,400	1,850	2,130	683 x 103	27,310	171 x 103	3,414
100 x 16	1,600	14.28	10.7	2,530	2,880	2,220	2,560	1.33 x 106	34,130	267 x 103	4,266
120 x 16	1,920	17.14	8.97	2,940	3,360	2,590	2,990	2.30 x 106	40,960	384 x 103	5,120
160 x 16	2,560	22.85	6.73	3,750	4,360	3,180	3,700	5.46 x 106	54,610	683 x 103	6,826
200 x 16	3,200	28.57	5.38	4,540	5,725	3,760	4,370	10.7 x 106	68,270	1.07 x 106	8,534
250 x 16	4,000	35.71	4.31	5,520	6,425	4,500	5,250	20.8 x 106	85,330	1.67 x 106	10,670
300 x 16	4,800	42.84	3.59	6,460	7,525	5,270	6,150	36.0 x 106	102 x 103	2.40 x 106	12,800