Copper Busbar

Copper Busbar Grades

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

 

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.

Get Free Ampacity Calculation

 

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

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 Options

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

 

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

Get a Quote in 2 Hours

Request a Sample Test Report

 

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)

 

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

 

Total Price = (LME Copper Price + Processing Fee) × Quantity + Shipping

Cost Component	Explanation
LME Copper Price	Official London Metal Exchange cash settlement price on your order confirmation day
Processing Fee	Covers cutting, punching, bending, plating, heat shrink, testing, and packaging
Shipping	Sea or air freight to your door (see shipping table above)

 

Real Pricing Examples (EXW Tianjin, processing fee only. Assumes LME Copper at $9,500/ton)

Busbar Specification	Processing Required	Quantity	Processing Fee (USD/piece)	Typical Landed Cost to USA (Sea Freight)
C11000, 50x5mm, 1000mm	Cut to length only	500 pcs	$0.85	$8.20 - $9.50
C11000, 50x5mm, 1000mm	Cut + 4 holes (10.5mm) + deburr	500 pcs	$1.60	$9.50 - $11.00
C11000, 80x8mm, 1500mm	Cut + 6 holes + 90° L-bend	200 pcs	$4.20	$28 - $34
C11000, 100x10mm, 2000mm	Cut + 8 holes + tin plating (8μm) + L-bend	100 pcs	$9.50	$68 - $82
C10200, 60x6mm, 800mm	Cut + 4 slotted holes + Z-bend + heat shrink	300 pcs	$3.80	$22 - $27

 

Key Notes

Processing fee decreases 15-25% when quantity reaches 1,000+ pieces or 3+ tons

Rush orders add 20% to processing fee

Send your drawing + quantity + grade + surface treatment for exact quote. Reply within 24 hours.

 

Sample & Small Batch Policy

Order Tier	Quantity Range	Best For	Processing Fee vs. Base Price	Lead Time
Tier 1 – Sample	1 – 50 kg (about 1-15 pieces)	Fitment test, material approval, functional check	Base + 40-60%	3-7 days
Tier 2 – Pilot Batch	51 – 500 kg (about 15-150 pieces)	Trial run, urgent shortage, limited production	Base + 15-25%	5-10 days
Tier 3 – Production	500+ kg (about 150+ pieces)	Full project, regular stock, bulk order	Base Price	7-12 days

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.

 

1. What copper grades do you offer?

C11000, C10200, C10100, and C10700. These are the four industry-standard grades for copper busbar.

C11000 is our most common grade – 98% IACS conductivity, suitable for 80% of applications. C10200 is oxygen-free copper, better for welding and deep bending. C10100 is high-purity (99.99%) for sensitive electronics. C10700 contains 0.1% silver, which prevents softening at high temperatures (200°C+). Tell us your application and we will recommend the right grade.

 

2. What is your actual conductivity? Not just "≥98% IACS"?

Our batches typically test between 98.4% and 98.9% IACS. We do not just claim "≥98%" – we measure every batch and keep records.

We use a calibrated conductivity meter (eddy current method) on every production batch. The lowest we have seen in the past 12 months was 98.2%. The highest was 99.1%. If you request, we will include the test report with your shipment. If you test the material yourself and find below 98%, we will refund double the value of that batch.

 

3. What tolerances can you hold?

Thickness: ±0.05mm. Width: ±0.10mm. Hole position: ±0.15mm. These are our standard guarantees.

For comparison, many suppliers hold ±0.10mm on thickness and ±0.30mm on hole position. The difference matters when you stack multiple busbars or mate with existing switchgear holes. For custom orders, we provide a first article inspection report showing every measured dimension before we run the full batch.

 

4. Can you make busbars from my drawing?

Yes. Send us any format – DXF, DWG, PDF, or even a hand sketch with a ruler.

We have CNC punching and bending machines that read CAD files directly. If you only have a sample part, we can measure it and create the drawing for you. There is no charge for drawing review or feasibility check. We will tell you if something cannot be made, or how to change it so it can.

 

5. Do you charge for engineering support?

No. Free. Before you order and after.

Many suppliers charge for drawing review, sample making, or technical consultation. We do not. You can email us with a problem, a drawing, or even just a photo of a failed busbar – and we will reply with our recommendation. No purchase required. No obligation.

 

6. What is the minimum bend radius?

1× thickness for soft copper. 1.5× for half-hard. 3× for hard copper.

If you bend tighter than these numbers, the copper will crack. This is not a defect – it is the physical limit of the material. For example, a 10mm thick half-hard busbar needs at least a 15mm bend radius. If your design requires a tighter bend, we can anneal the bend area (soften it) before bending. Tell us your requirement and we will tell you if it is possible.

 

7. Does bare copper need to be shiny to work?

No. Dark or brown copper still conducts electricity perfectly.

The shiny red color of new copper turns brown and then dark over time. This is surface oxidation (copper oxide). It is still conductive. Green corrosion (verdigris) is different – that indicates moisture and contamination, and it can cause problems. We ship bare copper with VCI paper to slow oxidation, but some darkening is normal and harmless.

 

8. Tin plating or heat shrink – which one do I need?

Tin plating is for corrosion and copper-aluminum connections. Heat shrink is for insulation and color coding.

If your busbar will be in a humid, outdoor, or marine environment, add tin plating. If you are connecting copper to aluminum, tin plating is required (to prevent galvanic corrosion). If you need electrical insulation or phase colors (yellow, green, red, blue, black), use heat shrink tubing. If you need both, we can plate first and then apply shrink tubing on top.

 

9. How do you calculate price?

LME copper price + processing fee + shipping = your landed cost.

We check the London Metal Exchange price on the day you order. Then we add our processing fee (cutting, punching, bending, plating, shrink – whatever you need). Then we add shipping (sea or air, to your door). We give you one all-inclusive price. No hidden fees. No surprises.

 

10. Can you hold a fixed price for my project?

Yes – for 7 days on standard orders. For longer, we can quote a fixed price with a volume commitment.

If you need to submit a bid to your customer, we can lock the copper price for 7 days at no charge. For longer-term contracts (3-6 months), we can quote a fixed price if you commit to a monthly volume. Otherwise, we can price based on LME average of the month before shipment.

 

11. What is your lead time?

1-3 days for bare copper cut to length. 10-12 days for fully fabricated with tin plating.

See breakdown:

Order Type	Lead Time
Bare copper, cut to length	1-3 days
+ Hole punching	3-5 days
+ Bending	5-7 days
+ Tin plating	7-10 days
+ Heat shrink	+1-2 days
Full fabrication (all of the above)	10-12 days

Rush service available (adds 20% to processing fee). Add shipping time on top.

 

12. Do you ship internationally?

Yes. We ship to North America, Europe, Australia, Southeast Asia, Middle East, and South America.

We use sea freight for standard orders (4-8 weeks total) and air freight for urgent orders (1-2 weeks total). We work with freight forwarders to handle customs clearance – you receive the busbar at your door. We provide tracking updates every step of the way.

 

13. What payment terms do you accept?

T/T bank transfer for most orders. L/C at sight for larger contracts.

T/T: 30% deposit to start production. 70% before shipping (or against copy of bill of lading for sea freight).

L/C: at sight, confirmed, for orders above $50,000.

PayPal / credit card: for sample orders only (under $1,000).

 

14. Do you provide samples before I order?

Yes. We can send you small samples (200-300mm length) for testing.

Sample fee applies (typically $50-100, depending on size and treatment). We deduct this from your first production order. Samples take 3-5 days to prepare plus shipping time. You can test conductivity, bending, plating adhesion – whatever you need to verify before placing a bulk order.

Henan Gnee New Material 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.