Robust Aluminum Bus Bars for Efficient Electrical Power Distribution

Introduction

Aluminum bus bars are commonly used as conductors in electrical distribution systems due to their high current capacity, lighter weight versus copper, and lower cost. They provide an efficient and economical means of consolidating electrical feeds into organized busways and buses.

Aluminum bus bars can replace cables for feeder circuits above 50A and are used extensively in switchgear, panelboards, motor control centers and other commercial/industrial applications. This guide provides an overview of the benefits aluminum bus bars offer and how systems are designed and installed.

Aluminum Bus Bar Benefits

Aluminum bus bars offer several advantages:

High Current Capacity

With conductivity about 60% that of copper, large aluminum bus bars efficiently carry hundreds or thousands of amps.

Lower Cost Than Copper

Aluminum costs much less than copper per pound. Aluminum bus bars offer big cost savings for high capacity systems.

Lightweight

Aluminum is nearly 1/3 the density of copper. This facilitates installation and reduces structural support needs.

Workability

Aluminum is malleable and can be bent on-site to suit layout requirements.

Corrosion Resistant

Proper alloy choice and anodization provide excellent corrosion resistance comparable to copper.

These factors make aluminum bus bar systems economical for centralized power distribution.

GRL Aluminum Bus Bar Offerings

GRL supplies aluminum bus bars in a range of sizes:

• 20mm x 5mm to 120mm x 15mm cross-sections
• Bar lengths up to 12 meters
• Ampacities from 50A to 6000A+

6061 and 6063 alloys provide optimal electrical and mechanical properties. Bus bars are anodized for corrosion protection. Accessories like insulators, brackets and joints are available.

GRL engineering expertise helps select appropriate bus bar designs tailored to electrical system needs. Contact GRL today for your aluminum bus bar requirements.

Installation Guidance

Proper installation of aluminum bus bar systems involves:

Layout Design

Layout should allow for efficient power distribution and prevent overheating.

Support and Bracing

Bus bars require secure mounting to prevent vibration/fatigue over decades of use.

Connection Termination

Mechanical lugs and connectors must be properly sized to conduct full rated current.

Expansion and Contraction

Aluminum expands more than copper. Adequate clearances must allow movement.

Careful installation ensures aluminum bus bars provide reliable power distribution with minimal losses.

Aluminum vs. Copper Bus Bars

Aluminum and copper bus bars have tradeoffs:

Electrical Differences

• Aluminum has 60% the conductivity of copper per cross-sectional area
• Larger aluminum bus bars are needed for equivalent ampacity
• Aluminum oxide layer does not hinder conductivity

Mechanical Differences

• Aluminum is lighter in weight than copper
• Aluminum is more flexible and easier to work than copper
• Aluminum corrodes more easily than copper without proper finishes

Relative Cost

• Aluminum bus bars cost much less than same-sized copper bars
• But aluminum requires 1.6x to 2x size for equivalent ampacity
• Aluminum saves cost in high current applications 500A+

Ideal Applications

• Copper better for lower current branch circuits
• Aluminum excels in high capacity main feeds 1000A+
• Outdoor applications favor aluminum for cost savings

In summary, aluminum provides a lighter weight and lower cost bus bar solution with tradeoffs of larger size and more corrosion considerations.