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Copper Busbars
Product Overview
Copper Busbars manufactured by R V Metal Corporation are engineered for high-current electrical distribution systems where superior conductivity, dimensional accuracy, and long-term reliability are critical. Produced from high-purity copper grades such as ETP and DHP, these busbars deliver excellent electrical performance with low resistive losses, making them ideal for power panels, switchgear assemblies, transformers, substations, and industrial electrical installations.
Our copper busbars are available in flat, rectangular, square, and customized profiles with tight thickness and width tolerances to ensure consistent current flow and ease of installation. Supplied in soft, half-hard, or hard temper conditions, they offer excellent formability for bending, punching, drilling, and surface finishing processes such as tinning, silver plating, or insulation coating.
Designed to meet international electrical and mechanical standards, R V Metal Corporation’s copper busbars are widely used by panel builders, OEMs, EPC contractors, and electrical consultants across power distribution, renewable energy, railways, EV infrastructure, and heavy industrial sectors. Each busbar is manufactured with strict quality control to ensure uniform grain structure, high conductivity, and dependable performance under continuous electrical load.
Technical Specifications
| Parameter | Specification |
|---|---|
| Product Name | Copper Busbars / Copper Bus Pipes |
| Material Grades | ETP Copper (C11000), DHP Copper (C12200), OFHC Copper (C10100 – on request) |
| Purity | ≥ 99.90% Copper (ETP / DHP) |
| Electrical Conductivity | ≥ 100% IACS (ETP), ≥ 97% IACS (DHP) |
| Oxygen Content | ETP: 200–400 ppm, DHP: ≤ 40 ppm |
| Forms Available | Flat Busbars, Rectangular Bars, Square Bars, Round Bus Pipes, Custom Profiles |
| Thickness Range | 2 mm to 50 mm (custom sizes available) |
| Width Range | 10 mm to 300 mm (as per drawing / requirement) |
| Length | Standard: 3 m, 4 m, 5 m, 6 m | Cut-to-length available |
| Temper | Soft (O), Half-Hard (H), Hard (H80) |
| Surface Finish | Mill Finish, Bright Finish, Electro-Tinned, Silver Plated (on request) |
| Dimensional Tolerance | As per ASTM / EN / IS standards or customer drawing |
| Fabrication Suitability | Excellent for Bending, Punching, Drilling, CNC Machining |
| Operating Temperature | -40°C to +250°C (depending on application) |
| Standards Compliance | ASTM B187 / B152, EN 13601, IS 1897, DIN, JIS (as applicable) |
| Inspection & Testing | Dimensional Check, Conductivity Test, Visual Inspection, Chemical Analysis |
| Documentation | Mill Test Certificate (MTC), Chemical & Mechanical Test Reports |
| Packing | Wooden Pallet Packing / Export Seaworthy Packing |
| Typical Applications | Electrical Panels, Switchgear, Transformers, Bus Ducts, EV Chargers, Substations |
Chemical Composition
| Element | ETP Copper (C11000) |
DHP Copper (C12200) |
OFHC Copper (C10100) |
|---|---|---|---|
| Copper (Cu) | ≥ 99.90% | ≥ 99.90% | ≥ 99.99% |
| Oxygen (O) | 0.020 – 0.040% | ≤ 0.040% | ≤ 0.0005% |
| Phosphorus (P) | — | 0.015 – 0.040% | — |
| Silver (Ag) | — | — | ≤ 0.002% |
| Iron (Fe) | ≤ 0.005% | ≤ 0.005% | ≤ 0.003% |
| Lead (Pb) | ≤ 0.005% | ≤ 0.005% | ≤ 0.003% |
| Zinc (Zn) | ≤ 0.005% | ≤ 0.005% | ≤ 0.003% |
| Other Impurities (Total) | ≤ 0.05% | ≤ 0.05% | ≤ 0.01% |
UNS Codes & Grades
| UNS Code | Copper Grade | Description | Typical Conductivity (% IACS) |
Common Applications |
|---|---|---|---|---|
| C11000 | ETP Copper | Electrolytic Tough Pitch Copper | ≥ 100% | Main LV/MV busbars, switchgear, panels, transformers |
| C10100 | OFHC Copper | Oxygen-Free High Conductivity Copper | ≥ 101% | High-end electrical, EV systems, electronics, power distribution |
| C10200 | OF Copper | Oxygen-Free Copper | ≥ 100% | Electrical busbars requiring hydrogen embrittlement resistance |
| C12200 | DHP Copper | Phosphorus-Deoxidized High Residual Phosphorus Copper | ≥ 97% | Welded busbars, brazed joints, fabricated assemblies |
| C12000 | DLP Copper | Phosphorus-Deoxidized Low Residual Phosphorus Copper | ≥ 99% | Electrical applications requiring better conductivity than DHP |
Mechanical, Physical & Fabrication Properties
| Property | C11000 (ETP Copper) |
C12200 (DHP Copper) |
C10100 / C10200 (OF / OFHC Copper) |
Remarks / Practical Notes |
|---|---|---|---|---|
| Density | 8.89 g/cm³ | 8.94 g/cm³ | 8.94 g/cm³ | Used for weight & short-circuit force calculations |
| Electrical Conductivity | ≥ 100% IACS | ≥ 97% IACS | ≥ 100–101% IACS | Critical for heat rise & current rating |
| Tensile Strength (Annealed) | 210 – 250 MPa | 220 – 260 MPa | 210 – 250 MPa | Varies with temper |
| Tensile Strength (Hard) | 300 – 350 MPa | 300 – 360 MPa | 300 – 350 MPa | Used for rigid, high-force busbar assemblies |
| Elongation (Annealed) | ≥ 35% | ≥ 30% | ≥ 35% | Higher elongation = better bending performance |
| Hardness (HV) | 45 – 60 HV | 50 – 65 HV | 45 – 60 HV | Depends on temper (O, H, HH) |
| Thermal Conductivity | ≈ 390 W/m·K | ≈ 360 W/m·K | ≈ 400 W/m·K | Direct impact on heat dissipation |
| Coefficient of Thermal Expansion | 16.5 ×10⁻⁶ /°C | 16.8 ×10⁻⁶ /°C | 16.5 ×10⁻⁶ /°C | Important for long busbar runs |
| Melting Point | 1083 °C | 1083 °C | 1083 °C | Same for all pure copper grades |
| Bending / Formability | Excellent | Very Good | Excellent | DHP preferred if heavy fabrication involved |
| Weldability | Poor | Excellent | Good | DHP chosen where welding is required |
| Brazing / Soldering | Good | Excellent | Excellent | Critical for laminated & jointed busbars |
| Machinability | Moderate | Moderate | Moderate | Sharp tooling recommended |
| Hydrogen Embrittlement Resistance | Poor | Excellent | Excellent | Why ETP is avoided in welded zones |
Common Names & International Identifiers
| Common / Trade Name | UNS Code | ASTM / ASME | EN / DIN | IS (India) | BS / JIS / Other Identifiers | Typical Industry Reference |
|---|---|---|---|---|---|---|
| Electrolytic Tough Pitch Copper (ETP) | C11000 | ASTM B187, ASTM B152 | EN CW004A | IS 5082 Cu-ETP | BS C101, JIS C1100 | General electrical busbars, switchgear |
| Deoxidized High Phosphorus Copper (DHP) | C12200 | ASTM B187, ASTM B152 | EN CW024A | IS 191 Cu-DHP | BS C106, JIS C1220 | Welded, brazed & fabricated busbars |
| Oxygen Free Copper (OF) | C10100 | ASTM B187 | EN CW009A | — | BS C103 | High-purity electrical & electronic busbars |
| Oxygen Free High Conductivity Copper (OFHC) | C10200 | ASTM B187 | EN CW008A | — | JIS C1020 | EV, railways, high-frequency applications |
| High Conductivity Copper Busbar | C11000 / C10200 | ASTM B187 | EN CW004A / CW008A | IS 5082 | BS / IEC compliant | Power distribution panels |
| Tinned Copper Busbar | C11000 (Tinned) | ASTM B187 + Tin Coating | EN CW004A | IS 5082 | IEC 61439 compatible | Corrosion-resistant busbar systems |
| Silver Plated Copper Busbar | C11000 (Ag Plated) | ASTM B187 + Ag Coating | EN CW004A | — | IEC / MIL references | High-current & low-contact-resistance joints |
| Laminated Copper Busbar | C11000 / C12200 | ASTM B187 | EN CW004A / CW024A | IS 5082 | IEC 61439 | Low inductance power electronics |
Standards & International Equivalents
| Standard Body | Standard Number | Copper Grade / Designation | Product Form Covered | Region / Acceptance |
|---|---|---|---|---|
| ASTM | ASTM B187 | C11000, C12200, C10100, C10200 | Rolled Copper Busbars, Bars & Flats | USA, Global Export |
| ASTM | ASTM B152 | C11000, C12200 | Copper Sheet, Strip & Busbar Stock | USA, Global |
| EN | EN 13601 | CW004A, CW024A | Copper Busbars for Electrical Purposes | Europe (EU) |
| EN | EN 13599 | CW004A | Copper Plates, Sheets & Busbars | Europe |
| DIN | DIN 43671 | E-Cu58 (ETP) | Copper Busbars | Germany / EU |
| IS | IS 5082 | Cu-ETP, Cu-OF | Electrical Copper Busbars & Conductors | India |
| IS | IS 191 | Cu-DHP | Phosphorus Deoxidized Copper | India |
| BS | BS 2872 | C101, C102, C106 | Copper & Copper Alloy Busbars | UK / Commonwealth |
| JIS | JIS H3140 | C1100, C1220 | Copper Busbars & Rolled Products | Japan / Asia |
| IEC | IEC 61439 | Material Neutral | Low Voltage Switchgear & Busbar Systems | Global (Panel Builders) |
| IEC | IEC 60228 | Class 1 Copper Conductors | Electrical Conductors & Busbars | Global |
Applications
| Industry / Sector | Application Area | Function of Copper Busbar | Preferred Copper Grade | Typical Standards Followed |
|---|---|---|---|---|
| Power Distribution | LT / HT Panels, PCC, MCC Panels | Main power distribution, load sharing | C11000 (ETP), C10200 (OF) | IEC 61439, ASTM B187, EN 13601 |
| Electrical Switchgear | ACB, VCB, SF6 Panels | High-current conduction with low losses | C11000, C10100 | IEC 62271, ASTM B187 |
| Renewable Energy | Solar Inverters, Combiner Boxes | DC & AC power collection and transfer | C11000, C10200 | IEC 61730, IEC 61439 |
| Electric Vehicles (EV) | EV Chargers, Battery Packs, BMS | High-current DC distribution | C10200 (OF), C10100 | IEC 61851, ISO 6469 |
| Data Centers | Busway Systems, PDU, UPS | Efficient power delivery with minimal voltage drop | C11000, C10200 | IEC 61439-6, ANSI C37 |
| Industrial Automation | PLC Panels, Drives, Servo Panels | Stable current supply for automation systems | C11000 | IEC 60204, ASTM B187 |
| Power Generation | Thermal, Hydro, Nuclear Plants | Generator output and auxiliary power transfer | C11000, C10200 | IEC 60034, EN 13601 |
| Railways & Metro | Traction Substations, Signaling Panels | High-reliability current transmission | C11000, C10200 | EN 50123, IEC 60850 |
| Oil & Gas | Explosion-Proof Panels | Safe high-current distribution in hazardous zones | C11000 | IEC 60079, ATEX |
| OEM Electrical Equipment | Transformers, Rectifiers, SMPS | Low-resistance internal connections | C11000, C10200 | ASTM B187, IEC 61558 |
Standard Copper Busbars Dimensional Chart
Copper Busbars – Dimensional Chart
| Busbar Type | Thickness (mm) | Width (mm) | Cross-Section Area (mm²) | Theoretical Weight (kg/m) | Available Forms | Typical Lengths |
|---|---|---|---|---|---|---|
| Flat Busbar | 5 | 25 | 125 | 1.12 | Flat / Edge-Rounded / Chamfered | 3 m / 4 m / 5 m / 6 m |
| Flat Busbar | 6 | 40 | 240 | 2.15 | ||
| Flat Busbar | 8 | 50 | 400 | 3.58 | ||
| Flat Busbar | 10 | 60 | 600 | 5.38 | ||
| Flat Busbar | 12 | 100 | 1200 | 10.75 | ||
| Flat Busbar | 15 | 120 | 1800 | 16.13 | ||
| Punched Busbar | 6 – 12 | 25 – 100 | As per drawing | As per section | Hole-punched / Slotted | Custom |
| Laminated Busbar | 0.8 – 2.0 (per layer) | 20 – 100 | Multi-layer | Calculated | Insulated Multi-Layer Stack | Custom |
| Tin-Plated Busbar | 5 – 15 | 25 – 120 | Standard / Custom | +2–4% over bare copper | Tin / Silver Plated | 3–6 m |
Weight (kg/m) = Thickness (mm) × Width (mm) × 0.00896
- Weights are theoretical and calculated at copper density 8.96 g/cm³.
- Tin / Silver plating increases weight by approx. 2–4%.
- Current rating depends on enclosure temperature, spacing, and orientation.
- Laminated busbars are preferred above 1,600 A to control skin effect and heat rise.
- Custom punching, bending, and insulation available as per OEM drawings.
Current Carrying Capacity vs Cross-Section (Bare Copper Busbars)
| Cross-Section (mm²) | Busbar Size (mm) | Current Rating (A) | Typical Application |
|---|---|---|---|
| 100 | 5 × 20 | 260 | LV Panels |
| 160 | 5 × 32 | 400 | DB / MCC |
| 250 | 6 × 40 | 630 | Power Panels |
| 400 | 8 × 50 | 1,000 | Main LT Panels |
| 600 | 10 × 60 | 1,400 | Transformer LT Side |
| 800 | 10 × 80 | 1,800 | High Load Feeder |
| 1,200 | 12 × 100 | 2,500 | Substation Panels |
| 1,800 | 15 × 120 | 3,600 | Main Bus Duct |
Temperature Rise vs Current Density (Engineer’s Reality Check)
| Current Density (A/mm²) | Temperature Rise | Acceptability |
|---|---|---|
| 1.2 | ~30 K | Excellent (Continuous Duty) |
| 1.6 | ~50 K | Industry Standard |
| 2.0 | ~70 K | Short Duration / Ventilated Panels |
| >2.2 | >90 K | NOT RECOMMENDED |
Tin-Plated vs Bare Copper Busbars (Why EPCs Ask)
| Parameter | Bare Copper | Tin-Plated Copper |
|---|---|---|
| Contact Resistance | Moderate (oxidizes) | Low & Stable |
| Corrosion Resistance | Low | High |
| Joint Reliability | Medium | Excellent |
| Maintenance | Higher | Low |
| Preferred Use | Internal dry panels | Outdoor / Humid / Marine |
Laminated Busbars – When Single Bars Fail
| Parameter | Solid Busbar | Laminated Busbar |
|---|---|---|
| Skin Effect | High above 1,600 A | Minimal |
| Inductance | High | Very Low |
| Heat Dissipation | Moderate | Excellent |
| Voltage Drop | Higher | Lower |
| Recommended For | <1600 A | EV Chargers, Inverters, UPS |
Spacing & Derating Factors (This Is What Consultants Catch)
| Condition | Derating Factor |
|---|---|
| Enclosed Panel (No Ventilation) | 0.85 |
| High Ambient (45 °C) | 0.90 |
| Vertical Mounting | 0.95 |
| Closely Spaced Busbars | 0.80 |
| Forced Air Cooling | 1.10 |
EPC-Grade Mandatory Notes (Non-Negotiable)
Important Engineering Notes:
- All current ratings are indicative and must be derated based on enclosure, ambient temperature, and installation method.
- Tin plating is strongly recommended for outdoor, coastal, and industrial environments.
- Laminated busbars are mandatory above 1,600 A for inverter, EV, and UPS systems.
- Improper busbar spacing leads to overheating, magnetic stress, and joint failure.
- Final busbar selection must comply with IEC 61439 / IS 8623 panel design norms.
