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Unlocking the Benefits of Aluminium Busbars

We produce Aluminium busbars to specification, down to 0.5mm, and offer powder coating, epoxy coating, heat shrink sleeving, and electroplating in tin, silver, and nickel to meet your specific requirements.

Our applications range from utilizing polyolefin and PVC for 11KVA switchgear in the energy and rail sectors, to more complex busbars for EV/Hybrid battery systems that are coated with a range of insulation materials, including resicoat HGF03R (red),  HFG03R (orange) and Nylon BB, to achieve ratings between 1.5 and 5KV.

In the world of electrical power distribution, busbars play a crucial role in efficiently transferring electricity from the source to various electrical components. Traditionally, copper has been the preferred choice for busbar materials due to its excellent conductivity and low resistance. However, the increasing demand for energy efficiency, cost-effectiveness, and environmental sustainability has led to a growing interest in the use of aluminum busbars.

Below, we will explore the numerous benefits that aluminium brings to the table as a reliable and efficient alternative for busbar applications.

Lightweight and Cost-effective

One of the key advantages of aluminium busbars is their significantly lower weight compared to copper. Aluminum weighs approximately one-third of copper, making it easier to handle, install, and transport. The reduced weight translates into cost savings not only during the manufacturing and installation process but also in terms of transportation costs. Additionally, as aluminium is more abundant and less expensive than copper, it offers a cost-effective solution without compromising on performance.

High Conductivity

While copper has long been revered for its exceptional conductivity, aluminium possesses a conductivity of around 61% that of copper. However, the lower conductivity is offset by the fact that aluminium busbars can be designed with larger cross-sectional areas, compensating for the difference. By employing larger dimensions, aluminium busbars can maintain comparable current-carrying capacities to copper busbars. Therefore, aluminium busbars can handle high current loads without sacrificing performance or safety.

Improved Thermal Performance

Aluminum’s excellent thermal conductivity plays a significant role in busbar applications. Due to its high thermal conductivity, aluminium busbars efficiently dissipate heat generated during power transmission. This characteristic enables efficient heat dissipation, reducing the risk of overheating and minimizing the need for additional cooling measures. As a result, aluminium busbars contribute to enhanced overall system reliability and longevity.

Corrosion Resistance

Aluminium possesses natural corrosion resistance, making it an ideal choice for busbar applications in humid or corrosive environments. Unlike copper, which requires additional protective coatings or insulation to prevent corrosion, aluminium busbars can resist oxidation and maintain their integrity over time. This inherent corrosion resistance minimizes maintenance requirements, extends the lifespan of busbar systems, and enhances their overall reliability.

Eco-Friendly Solution

In an era focused on sustainability, aluminium busbars offer a greener alternative to copper. Aluminum is a highly recyclable material, requiring significantly less energy for recycling compared to the production of primary aluminium. By using aluminium busbars, businesses can reduce their carbon footprint and contribute to a more environmentally friendly power distribution infrastructure.

Design Flexibility

Aluminum’s malleability and versatility allow for greater design flexibility in busbar systems. Its ability to be easily shaped and formed enables the production of complex busbar configurations, facilitating customized solutions for specific applications. This flexibility also simplifies installation, enabling easier integration into various electrical systems and equipment.


The advantages of using aluminium busbars for power distribution are undeniable. From lightweight construction and cost-effectiveness to high conductivity, improved thermal performance, and corrosion resistance, aluminium provides a compelling alternative to copper. Moreover, its eco-friendliness and design flexibility make it a preferred choice for modern electrical systems. As industries strive for enhanced efficiency and sustainable solutions, aluminium busbars stand out as a reliable and innovative option, delivering superior performance while minimizing environmental impact.

Contact us to discuss your requirements.

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