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 electrical and thermal resistance, high mechanical strength in tension, compression and shear, and high resistance to fatigue failure properties, to name a few. Our copper Busbars are a key component of electrical utilities such as switchgear, panel boards, and busway enclosures for local high current power distribution but can be used for any application that fits your specification.

Alternatives to Copper

Aluminium is the main alternative and has many positive attributes that will lend themselves to specific tasks and applications, but 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 a 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 fluctuations that may be encountered under service conditions require a certain amount of flexibility to be allowed for in the design. The greater hardness of copper compared with aluminium provides improved resistance to damage that may occur during installation and whilst in service. Reliability is a key factor in 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, which 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, and 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, and on projects where high performance, versatility and reliability are required, this product will stand the test of time

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

Sample Copper Busbars can be produced on request

Our copper Busbar manufacture can include: