Advantages of Busbar Trunking Systems
Busbar trunking systems are a method of power distribution using formed aluminum or copper bus bars made by a
busbar bending machine
to distribute the power around a building. Busbar systems were initially developed to provide an alternative to the more traditional methods of power distribution and to resolve many of the longstanding issues with cables.
Summary of Advantages Over Cables
- Easier branching
- More strength than cable
- Flexibility
- Better electrical current conduction
- Lower lifetime cost
Easier Branching
By creating a hole on the bus bar with the busbar punching machine (see also
sheet metal punching machine), and with the help of bolts and nuts, you can easily branch from the busbar and there is no need for terminals, etc.
More Strength Than Cable
Busbars have much better resistance than cables, and this shows especially in short-circuit testing. Within the casing of the busbar, there is a minimum distance between each conductor which reduces inductive reactance. A busbar’s flat profile also promotes optimal current density distribution and lowers resistance. As a result, voltage drop in a busbar run is typically lower than in equivalent cable runs.
Flexibility
Busbar is able to fit in many layouts and offers a more modular design than cables. They can be bent, punched and cut with the help of a
bus bar machine.
Busbars can be relocated with far less rework cost, and they can be modified to fit additional loads or changed routes. Once cables are installed, moving, changing, reconfiguring, and expanding can become expensive and disruptive. Busbar sections can be added, reconfigured, or replaced with minimal interruption to operations.
Better Electrical Current Conduction
Because high-frequency current tends to travel near the surface of a conductor (skin effect), a flat busbar with the same cross-sectional area as a cable usually provides a greater surface perimeter and therefore lower AC resistance. Practically, this translates to improved conductivity and reduced losses versus bundled cables of comparable ampacity.
Lower Lifetime Cost
It’s often assumed that busbar is a higher-cost alternative to cable. In practice, fast modular installation and reduced material handling make busbar highly competitive on CAPEX, and markedly better on OPEX. Over its life, the system can cost less than cables thanks to lower losses, easier inspections, minimal maintenance, and straightforward expansion. Accurate load planning and modular ratings also help estimate costs earlier in the project and with greater confidence.
Busbar Trunking vs Cable Systems
While cables have been widely used for decades, the modern shift toward busbar trunking systems is driven by measurable gains in performance, safety, and scalability. Global best practices and conformity assessment are documented in
IEC 61439 standards,
which set requirements for low-voltage switchgear and busbar trunking assemblies and help ensure consistent safety and reliability in real-world conditions.
- Space efficiency: Compact, enclosed runs reduce the need for large cable trays and simplify routing in risers and corridors.
- Modularity: Tap-off points and standardized sections enable fast reconfiguration with minimal downtime.
- Safety & reliability: Enclosed conductors, tested joints, and coordinated accessories help mitigate risks compared to open cable bundles.
The Role of Copper Busbars
Copper is the dominant choice for busbars due to excellent conductivity, thermal performance, and mechanical strength. Compared with aluminum, copper typically delivers lower resistive losses and superior short-circuit withstand—key benefits in high-current switchgear, panel boards, and energy-intensive facilities.
Precision fabrication is critical: with modern bending, punching, and cutting, copper bars are formed to exact specifications. This accuracy improves joint integrity, reduces waste, and ensures repeatable quality across large projects.
Impact of Copper Bending Machines on Fabrication Quality
- High precision: CNC-controlled angles and radii keep tolerances tight and repeatable.
- Time efficiency: Integrated cut–punch–bend workflows compress lead times and assembly hours.
- Cost savings: Lower scrap rates and reduced manual rework drive down unit costs.
- Operator safety: Enclosed stations and emergency-stop logic support safer daily operations.
These gains translate into consistent electrical performance, cleaner installations, and faster commissioning—benefits that compound across multi-floor commercial buildings, industrial plants, and data centers.
Cost Considerations and Total Cost of Ownership
Although a busbar trunking system may show slightly higher initial material costs in some specifications, the overall project economics are often superior. Faster installation reduces labor, modular tap-offs shorten downtime for changes, and lower electrical losses improve energy efficiency. Over the system lifecycle, these attributes typically outperform cable-based alternatives in both technical and financial terms.
Conclusion
Busbar trunking systems provide a future-ready platform for safe, efficient, and scalable power distribution. From easier branching and better current conduction to modular expansion and lower lifetime cost, the benefits are clear. When combined with modern copper bar fabrication using advanced
busbar bending machines, these systems deliver the precision, reliability, and speed that modern facilities demand.
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