Copper Busbar
Why Trust Us
Material Guarantee
99.95% pure electrolytic copper (Grade T2 / C11000), sourced from Jiangxi Copper and Yunnan Copper – China's top smelters. Each batch is traceable to its original furnace number.
Certification
SGS Test Report available upon request – covering conductivity, composition, and dimensional accuracy.
图片尺寸 350x350
Title
Material & Conductivity Performance
Copper Busbar Grades – Market Standards
| ASTM | EN | JIS | Purity | Conductivity | Key Feature |
|---|---|---|---|---|---|
| C11000 | CW004A | C1100 | ≥99.9% | 98-101% IACS | Electrolytic tough pitch, most economical |
| C10200 | CW007A | C1020 | ≥99.95% | 99-101% IACS | Oxygen-free, weldable |
| C10100 | CW008A | C1011 | ≥99.99% | 101-102% IACS | Oxygen-free electronic, ultra-high purity |
| C10700 | — | — | ≥99.9% + 0.1% Ag | 98-100% IACS | Silver-bearing, creep resistant |
Which Grade Should You Choose?
| If you need... | Choose... | Why |
|---|---|---|
| Lowest cost, standard application | C11000 | 98% IACS is enough, ready stock |
| Welding or soldering on busbar | C10200 | No hydrogen embrittlement |
| Ultra-high conductivity + purity | C10100 | 101-102% IACS, but premium price |
| High-temperature operation (200-300°C) | C10700 | Silver prevents grain growth and creep |
| Salt spray / outdoor | C11000 or C10200 | Grade doesn't matter; add tin plating |
Ampacity & Temperature Rise Control
What is ampacity? Why does it matter?
Ampacity = how much current (amps) a busbar can carry before it gets too hot.
If you undersize your busbar, it will overheat. Overheating melts insulation, damages equipment, and can start a fire.
Which Copper Grade Carries More Current?
Not all copper is the same. Higher purity = higher conductivity = more current in the same size.
| Grade | Purity | Conductivity | |
|---|---|---|---|
| C11000 (standard) | 99.9% | 98% IACS | Good enough for most jobs. Lowest cost. |
| C10200 (oxygen-free) | 99.95% | 99-101% IACS | Slightly more current. Can be welded. |
| C10100 (high-purity) | 99.99% | 101-102% IACS | Highest current in the same size. Most expensive. |
| C10700 (silver-bearing) | 99.9% + silver | 98-100% IACS | Same current as C11000, but handles heat better. |
Simple rule: If you need the absolute maximum current in a tight space, choose C10100. If budget matters more, choose C11000.
Busbar Size vs. Current – What Size Do You Need?
For C11000 (standard copper, 98% IACS) at normal conditions (40°C, open air):
| If You Need This Much Current... | Use This Size Busbar... | How Much Current It Actually Carries | Safe? |
|---|---|---|---|
| 400A | 30mm × 5mm | 430A | ✅ Yes |
| 500A | 40mm × 5mm | 520A | ✅ Yes |
| 600A | 50mm × 5mm | 610A | ✅ Yes |
| 800A | 60mm × 8mm | 960A | ✅ Yes |
| 1000A | 80mm × 8mm | 1160A | ✅ Yes |
| 1200A | 80mm × 10mm | 1360A | ✅ Yes |
| 1500A | 100mm × 10mm | 1580A | ✅ Yes |
| 1800A | 120mm × 10mm | 1800A | ⚠️ Borderline – go bigger |
| 2000A | 120mm × 12mm or two 100×10 | 2000A+ | ✅ Yes |
Real-World Conditions That Reduce Ampacity
Your busbar won't be in a perfect lab. Here's what hurts performance:
| Condition | What Happens | Multiply Ampacity By | Example: 1000A Busbar → Actually Becomes |
|---|---|---|---|
| Hot room (50°C instead of 40°C) | Less cooling | ×0.88 | 880A |
| Multiple bars touching (3+ bars side by side) | Can't cool down | ×0.80 | 800A |
| Inside a sealed box (no airflow) | No ventilation | ×0.80 | 800A |
| High altitude (2000m+) | Thinner air = less cooling | ×0.92 | 920A |
| Combination of above | Multiple problems | Multiply all factors | Ask us to calculate |
Example – A Real Installation:
You need 1000A. You have 3 busbars side by side inside a sealed panel, and the room is 50°C in summer.
Calculation: 1000A × 0.80 (side by side) × 0.80 (sealed) × 0.88 (hot room) = only 563A actual capacity
Solution: Your 1000A busbar will overheat. You actually need a busbar rated for 1000A ÷ 0.56 = 1785A → choose 100×10mm or upgrade to C10100.
Don't guess and risk overheating. Send us your specs. We'll calculate the right size for free.
Fabrication Precision & Bending Process
Dimensional Tolerances
| Dimension | Typical Supplier | Our Standard | Why It Matters |
|---|---|---|---|
| Thickness | ±0.10mm | ±0.05mm | Stacking multiple bars – errors add up |
| Width | ±0.20mm | ±0.10mm | Fits into terminal blocks |
| Length (6m bar) | ±5mm | ±1mm | Cuts to exact panel size – no trimming |
| Hole diameter | ±0.20mm | ±0.10mm | Bolt fits without play |
| Hole position (center to edge) | ±0.30mm | ±0.15mm | Matches existing switchgear holes |
| Hole position (center to center) | ±0.30mm | ±0.15mm | Multiple holes must align |
| Flatness (per 500mm) | ±0.30mm | ±0.10mm | No rocking when mounted |
| Bend angle | ±2° | ±1° | Fits into assembly without forcing |
Bending Capabilities – What Shapes Can We Make?
| Bend Type | Description | Typical Application | Max Size We Can Bend |
|---|---|---|---|
| Single L-shape | 90° bend at one end | Battery terminal connections | 120×12mm |
| Z-shape | Two opposite 90° bends | Stepped connections | 100×10mm |
| U-shape | Two same-direction 90° bends | Busway joints | 100×10mm |
| Offset bend | Slight angle to shift centerline | Aligning mismatched terminals | 80×8mm |
| Multi-bend custom | Any combination of above | Complex switchgear layouts | Send drawing for review |
Minimum bend radius (rule of thumb):
| Copper Hardness | Minimum Bend Radius | Example: 10mm thick bar |
|---|---|---|
| Soft (M) | 1 × thickness | 10mm radius |
| Half-hard (Y2) | 1.5 × thickness | 15mm radius |
| Hard (Y) | 3 × thickness | 30mm radius |
Why Busbars Crack During Bending
| Cause of Cracking | Our Prevention |
|---|---|
| Material too hard | We label hardness clearly. You choose. |
| Burrs from slitting | We deburr all cuts – 400 grit sanding pass |
| Internal stress from straightening | Stress-relief annealing before bending |
| Wrong bend radius | We check your drawing and recommend changes |
| Impurities in copper | We only use Grade A cathode – full traceability |
Hole Punching
| Problem | What Goes Wrong | How We Prevent It |
|---|---|---|
| Burr on hole back side | Bolt won't sit flat. Nut strips threads. | Hydraulic punching with sharp dies. Deburring after. |
| Hole too small | Bolt doesn't fit. Field drilling required. | First article inspection. Pin gauge test. |
| Hole pattern misaligned | Bar doesn't mount. Scrap. | CNC punching – not manual. Every hole in one setup. |
| Oval holes (punched off-center) | Weak connection. Loose bolt. | Servo-controlled punch position ±0.10mm. |
Standard hole options we support:
| Hole Type | Sizes Available | Typical Use |
|---|---|---|
| Round | 6.5mm, 8.5mm, 10.5mm, 12.5mm, 14.5mm, 16.5mm | M6, M8, M10, M12, M14, M16 bolts |
| Slotted / oval | 8.5×13mm, 10.5×15mm | Thermal expansion adjustment |
| Square / custom | By drawing | Specific terminal requirements |
Surface Treatment
Surface Treatment Options – What You Should Choose
| Treatment | Appearance | Salt Spray Hours | Lifespan (Typical Environment) | Best For | Relative Cost (vs. Bare Copper) |
|---|---|---|---|---|---|
| Bare copper | Shiny red-brown, then darkens naturally | N/A | 1-2 years (then dark but still works) | Indoor switchgear, dry panels, transformers | Base (1×) |
| Tin plating (matt) | Silver-gray | 72h (no red rust) | 5-8 years | Humid environments, marine, battery packs | +15–25% |
| Tin plating (bright) | Silver-shiny | 72h | 5-8 years | Customer specs (same protection as matt) | +15–25% |
| Nickel plating | Yellow-silver | 96h+ | 10+ years | High heat (200°C+), sulfur-rich environments | +30–50% |
| Silver plating | White-bright | N/A (not for corrosion) | N/A | High-frequency, high-conductivity contacts | +100–200% |
| Heat shrink tubing | Color-coded (yellow/green/red/blue/black) | Full protection | Lifetime of tubing | Insulation + phase identification | +5–15% |
Tin Plating – For Corrosion Protection & Copper-Aluminum Connection
| Type | Appearance | Salt Spray | Best For | Cost vs. Bare Copper |
|---|---|---|---|---|
| Matt tin | Matte silver-gray | 72h | General switchgear, busway | +15–25% |
| Bright tin | Shiny silver | 72h | Customer spec (same protection) | +15–25% |
| Reflowed tin | Smooth, semi-shiny | 96h+ | Marine, offshore, high humidity | +20–30% |
Our Tin Plating Process
| Process Step | Our Method |
|---|---|
| Pre-cleaning | Alkaline degrease + acid dip + water rinse |
| Plating thickness | Minimum 8μm, typically 12μm |
| Reflow / re-melt | Yes – 260°C IR reflow |
| Adhesion test | Tape test per ASTM B571 |
| Thickness check | X-ray fluorescence (XRF) on every batch |
| Post-rinse | Deionized water + hot air dry |
Heat Shrink Tubing – When You Need Insulation
| Color | Meaning (Typical) | Standard | Our Stock |
|---|---|---|---|
| Yellow | Phase A / L1 | IEC 60446 | ✅ |
| Green | Phase B / L2 / Earth (green/yellow stripe) | IEC 60446 | ✅ |
| Red | Phase C / L3 | IEC 60446 | ✅ |
| Blue | Neutral / DC negative | IEC 60446 | ✅ |
| Black | DC positive / general | General | ✅ |
| Clear | Inspection / no color code | General | ✅ |
Options we offer:
| Property | Standard Wall | Thin Wall | Heavy Wall |
|---|---|---|---|
| Thickness | 0.8-1.2mm | 0.4-0.6mm | 1.5-2.0mm |
| Voltage rating | 600V | 300V | 1000V+ |
| Shrink ratio | 2:1 | 3:1 | 2:1 |
| Best for | General busbar insulation | Tight spaces | High voltage / abrasion |
Specifications & Customization
Standard Sizes – Ready Stock
| Width (mm) | Thickness (mm) | Length (mm) | Weight (kg/m) | Stock Status |
|---|---|---|---|---|
| 20 | 3, 4, 5 | 6000 | 0.53 – 0.89 | ✅ In stock |
| 25 | 3, 4, 5 | 6000 | 0.67 – 1.11 | ✅ In stock |
| 30 | 3, 4, 5, 6 | 6000 | 0.80 – 1.60 | ✅ In stock |
| 40 | 4, 5, 6, 8 | 6000 | 1.42 – 2.84 | ✅ In stock |
| 50 | 5, 6, 8, 10 | 6000 | 2.22 – 4.45 | ✅ In stock |
| 60 | 6, 8, 10 | 6000 | 3.20 – 5.34 | ✅ In stock |
| 80 | 6, 8, 10, 12 | 6000 | 4.27 – 8.54 | ✅ In stock |
| 100 | 6, 8, 10, 12 | 6000 | 5.34 – 10.68 | ✅ In stock |
| 120 | 10, 12 | 6000 | 10.68 – 12.82 | ✅ In stock |
Customization
| Service | Details | Lead Time |
|---|---|---|
| Cutting to length | Any length from 100mm to 6000mm | 1-2 days |
| Hole punching | Round, slotted, square – any pattern | 2-3 days |
| Bending | L-shape, Z-shape, U-shape, offset, multi-bend | 3-5 days |
| Tin plating | Matt, bright, or reflowed – 8μm minimum | 3-5 days |
| Heat shrink | Any color – single or dual wall | 2-3 days |
| Nickel plating | For high heat or aggressive environments | 5-7 days |
| Complete fabrication | Punch + bend + plate + shrink – ready to install | 7-10 days |
Real projects. Real results
Switchgear Manufacturer – Vietnam
Problem: 30% of holes misaligned. 8 hours of rework per week.
We fixed it: CNC punching from CAD drawing. Pin gauge check on every piece.
Result: Failure rate <1%. Rework down to 30 min/week. No other supplier in 3+ years.
EV Battery Pack – Germany
Problem: 15% of bent busbars cracked after plating.
We fixed it: C10200 copper + stress-relief annealing + larger bend radius.
Result: Crack rate <0.5%. Saved €12k/month. 2,000+ pieces/month from us.
Data Center Busway – USA
Problem: 400m tin-plated busbar needed in 4 weeks. Supplier said 8 weeks.
We fixed it: Rushed stock + 3 shifts plating + air freight for half order.
Result: Delivered in 3.5 weeks. Avoided $50k/day penalty.
Offshore Wind Substation – Scotland
Problem: Standard tin plating failed salt spray at 48h. Needed 96h+.
We fixed it: Reflowed tin + 12μm thickness + sealant.
Result: Passed 120h salt spray. Preferred supplier for next 3 projects.
Transformer Manufacturer – Brazil
Problem: Busbars arrived scratched and dented. Customer rejected.
We fixed it: Foam interleaving + cardboard sleeves + corner protectors.
Result: Zero damage in 20+ shipments since. Customer audit passed.
Mining Equipment – Australia
Problem: High vibration loosened bolts every 3 months. Frequent shutdowns.
We fixed it: Spring washers + thread locker + torque sticker on each bar.
Result: Connections still tight after 14 months. No unplanned downtime.
Testing & Quality Control
How We Test
| Test Item | Method | Equipment | Pass Standard | Frequency |
|---|---|---|---|---|
| Conductivity | Eddy current / DC bridge | Sigmascope / Micro-ohmmeter | ≥98% IACS | Every batch |
| Cu purity | Spectrometer | Optical emission spectrometer | ≥99.9% | Every melt |
| Thickness tolerance | Micrometer | Digital caliper | ±0.05mm | 10 pcs per batch |
| Width tolerance | Micrometer | Digital caliper | ±0.10mm | 10 pcs per batch |
| Hole position | Pin gauge | Go/no-go pins | ±0.15mm | 100% |
| Flatness | Dial gauge + surface plate | Precision granite plate | ≤0.05mm/200mm | 5 pcs per batch |
| Tin plating thickness | XRF | X-ray fluorescence | ≥8μm | Every plating batch |
| Salt spray (plated) | ASTM B117 | Salt spray chamber | 72h no red rust | Per customer request |
| Hardness | Rockwell / Vickers | Hardness tester | As specified | Per batch |
Our Quality Checks
| Stage | Check | Action if Failed |
|---|---|---|
| Raw material arrival | Spectrometer test | Reject whole lot |
| After slitting | Width + thickness + burr check | Adjust slitter or scrap |
| After punching | Hole position + burr (100%) | Re-punch or scrap |
| After bending | Angle + crack inspection (visual + gauge) | Re-bend or scrap |
| After plating | Thickness + adhesion (XRF + tape test) | Re-plate or scrap |
| Before packing | Surface cleanliness + final visual | Clean again or reject |
| Before shipping | Packing check + label verification | Re-pack |
Anti-Oxidation Packaging
Our 6-Layer Protection System
| Layer | Material | Purpose |
|---|---|---|
| 1 (inner) | VCI paper (vapor corrosion inhibitor) | Prevents oxidation – wraps directly on copper |
| 2 | Foam interleaving | Prevents scratches between bars |
| 3 | Plastic stretch film | Seals out moisture and dust |
| 4 | Cardboard sleeve | Protects edges and surface |
| 5 (outer) | Wooden crate or heavy cardboard box | Structural protection for shipping |
| 6 | Corner protectors | Prevents strap damage |
How We Pack for Different Destinations
| Destination | Packaging We Use | Extra Protection if Requested |
|---|---|---|
| Domestic (truck) | VCI + foam + cardboard | Heat shrink wrapping |
| International (sea freight) | VCI + foam + stretch film + wooden crate | Desiccant bags inside |
| High humidity region (Southeast Asia, coastal) | VCI + foam + film + wooden crate + desiccant | Vacuum sealing |
| Long-term storage (>6 months) | VCI + film + sealed plastic bag | Nitrogen flushing (upon request) |
Lead Time & Shipping
Production Lead Time
| Order Type | Standard | Rush (extra 20%) |
|---|---|---|
| Bare copper, cut to length | 1-3 days | Same day |
| + Hole punching | 3-5 days | 2 days |
| + Bending | 5-7 days | 3-4 days |
| + Tin plating | 7-10 days | 5-7 days |
| + Heat shrink | +1-2 days | +1 day |
| Full fabrication (punch + bend + plate + shrink) | 10-12 days | 7-8 days |
Shipping Time & Cost – 1 Ton Copper Busbar (Actual Weight: 1000kg, Volume: ~0.12 CBM)
| Destination | Sea Freight (LCL) | Air Freight | ||
|---|---|---|---|---|
| Time | Cost (USD) | Time | Cost (USD) | |
| USA (West Coast) | 25-35 days | $150-250 | 5-7 days | $2,500-4,000 |
| USA (East Coast) | 35-45 days | $200-350 | 6-8 days | $3,000-5,000 |
| Europe (Rotterdam) | 30-40 days | $150-250 | 5-7 days | $2,500-4,000 |
| UK | 35-45 days | $200-300 | 5-7 days | $2,500-4,000 |
| Southeast Asia | 7-15 days | $50-120 | 2-4 days | $1,500-2,500 |
| Middle East (Jebel Ali) | 20-30 days | $120-200 | 4-6 days | $2,000-3,000 |
| Australia | 20-30 days | $120-200 | 4-6 days | $2,000-3,000 |
| South America (Brazil) | 40-55 days | $300-500 | 6-10 days | $4,000-6,000 |
Our Production Equipment
| Equipment | Quantity | What It Does |
|---|---|---|
| CNC hydraulic punching machine | 4 units | Hole punching. Position accuracy ±0.1mm. |
| CNC electric bending machine | 3 units | L-shape, Z-shape, U-shape. Angle accuracy ±1°. |
| Hydraulic slitting line | 2 lines | Cuts copper coils to exact width. Tolerance ±0.1mm. |
| Automatic cutting machine | 2 units | Cuts to length. Tolerance ±1mm per 6m. |
| Automated tin plating line | 1 line | 8μm minimum thickness. XRF tested every batch. |
| Heat shrink oven | 2 units | Applies tubing evenly – no bubbles, no burns. |
| Deburring machine | 2 units | Removes sharp edges from cuts and holes. |
Gnee Steel (Tianjin) Co., Ltd. is one of the leading copper busbar manufacturers and suppliers in China. We warmly welcome you to buy cheap copper busbar for sale here from our factory. All customized copper products are with high quality and competitive price.