Busbar is a metallic strip used for electrical power distribution that makes it easier, less expensive, and more flexible compared to traditional cabling. Common sizes for commercial and industrial applications range from 40 to 1200 amps. Copper busbar is preferred for its high conductivity, durability, and lifespan, though aluminum is also used. Busbars can be segregated with barriers between phases, non-segregated in a common enclosure, sandwiched between insulation, or air insulated. Installing busbars provides benefits over cabling like compact design, better heat dissipation, flexibility, cost savings, improved resistance, lower energy losses, and easier distribution.

1. Basics of Electrical Busbar - Residential & Commercial Projects
S.Sudha Velan B.E (Civil)

2. Electrical Busbar
Busbar is a metallic strips of copper & Aluminium conductor which
is used for electrical power distribution. The Bus bars that makes
the electrical power distribution much easier , less expensive and
more flexible.

4. Common commercial and industrial busbar sizes
• 40 Amp
• 50 Amp
• 60 Amp
• 100 Amp
• 225 Amp
• 250 Amp
• 400 Amp
• 800 Amp
• 1200 Amp

5. The most common sizes of the bus-bars are:
• 40×4mm (160 mm2)
• 40×5 mm (200 mm2)
• 50×6 mm (300mm2)
• 60×8 mm (480 mm2)
• 80×8 (640 mm2)
• 100×10 mm (1000 mm2)

6. Copper Busbar
• High conductivity
• Resistance to damage
• Higher performance in clamped joints
• Lower coefficient of linear expansion
• Long lifespan
• High recovery value
• Higher modulus of elasticity
• The surface of copper naturally oxidizes forming a thin hard layer
on the surface which remains conductive.
• Exposed aluminum surfaces also form an oxidized film. However,
this film is not conductive and leads to long term reliability issues
with joints.

7. Segregated Phase Busbar
• Segregated phase bus duct has all phase conductors in a
common enclosure with metal barriers between adjacent
phases.
• Range - 630A-5000 A
• Power generating plants , Industrial, inter connections switch
gear to transformers.

8. Non - Segregated Phase Busbar
• Non-segregated bus duct is where all the phase bars are in one
common metal enclosure with no barrier between phases.
• Range - 630A-6000 A ; 415 V to 1100 V
• Inter connections switch gear to transformers ,Switch gear to
switch gear.

9. Sandwich Busbar
• Copper - 630A-6300A
• Aluminium - 400A-5000A
• Transformer to Switchgear Panels
• Interconnection between Switchgear Panels
• Diesel Generator to Synchronizing / Switchgear Panels
• Rising mains or Vertical distribution
• Horizontal distribution

11. Air Insulated Busbar
• Copper 125A-1250A
• Aluminium 200A-800A
• Rising Mains or Vertical distribution
• Horizontal distribution

12. Sandwitch BusBar Air Insulated BusbarType

13. Light Trunking Busbar
• Copper 25A, 40A
• Horizontal distribution

14. Isolated Phase Busbar
• The Isolated Phase Bus (IPB) is used to carry very large currents,
typically between a generator and a step-up transformer, in power
generation facilities.
• Each phase conductor is enclosed in its own separate grounded
metal housing, with each housing separated from each other by
air
• Designed to carry continuous current ratings of 3,000 amperes to
45,000 amperes, and rated for voltages from 5 kV on up to about
38kV.

16. Cast Resin Insulated Busbar
• Compact and maintenance-free cast resin insulated bus bar
systems with copper or aluminium conductors for transmission of
energy between 513A - 6300A.
• Very compact: up to 50% more compact than metal enclosed
systems
• No fire barrier required due to 3 hour fire rated construction

19. Installing Busbars over conventional cabling has a range of advantages
• Design: Busbars have a compact design through which compressed
flat conductors can pass through the enclosure. Due to the compact
designs, busbars require lesser space than traditional cabling systems
• Heat Absorption: Since the design is compact and has a metal casing
with well-defined surface, bus bars can absorb heat generated while
transmissions and distribution of electricity in the walls of the
enclosure. The system of cooling is much better than traditional
cabling system.
• Flexibility: Bus bars are more flexible in nature compared to cables in
the sense that it can be used in any kind of structure with any
configuration. They are easily modifiable and hence the addition of
an extra room or building can be easily done. Bus bars can also be
relocated without much of a capital expenditure.

20. • Cost Savings: Bus bars can be mounted easily than a cable and
incurs a lesser cost of installation than traditional cables. They can
also be mounted at a lesser time than traditional cables.
• Better Resistance: Bus bars have rigid design elements and hence
has better resistance than cables, especially in case of short
circuits. Busbars have a minimum distance between the
conductors which in turn reduces the induction of resistance.
• Reduced Loss of Energy: Busbars have lower resistance than
cables. Hence the loss of energy due to transmission and
distribution is lower in Bus bars.

21. • Lower Electromagnetic Field: Due to the compact design and the
steel shell, a comparatively lower electromagnetic field is created
around a Busbar as compared to a cable. Hence, high loads of
4000 ampere to 5000 ampere can easily be created near the data
cables which is free from electromagnetic interference.
• Ease of Distribution: Bus bars help in easy, efficient and safe
distribution of line with the junction boxes in places where they
are required. Moreover, the location data junction boxes can be
changed whenever and where-ever in the future. The junction
boxes can be easily increased in the future as well with bus bars.
• Safe and Secured: Busbars are fitted with a steel casing and
cannot be damaged by rodents as compared to cables.

24. Electrical Panel Busbar:
• Busbars are metal bars used to carry large amounts of current.
Often made of copper or aluminum and every home electrical
panel has bus bars to distribute ac power to the rows of circuit
breakers .

32. THE RULES OF REJECTION
Reach for higher ground and they slap your hand,
Keep reaching.
Expect to be successful and they call you a dreamer,
Dream on.
Jump at a good opportunity and be labeled unstable,
Jump higher.
Every thing happens for a reason,
You be the reason .
Challenge the norm and be labeled a rebel,
Lead a rebellion.
Tolerance is often mistaken for weakness,
Be tolerant anyway.
Ideas sprout from the seeds of rejection,
Go get rejected.
Open your heart to minds that have closed.
Take joy in their opening.
Notice a strength in everyone you meet
You will become stronger.

33. Thanks & Regards
S.Sudha Velan