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What material is a bus bar made of?

Updated: 8/10/2023
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11y ago

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with dc solid copper or aluminum

with 60 Hz ac inductance will force current to the outer surface if the conductor

so the busses in substations are generally aluminum or copper tubing

power transmission lines are steel cable with 1/8" aluminum sheath

high frequency or rf busbars and wire is generally tubing that is silver plated

the inductance lets current flow only in the very thinnest skin of the conductor

CommentThe 'skin effect' at a mains' frequency of 50 - 60 Hz is not significant, and does not force current towards the outer surface of conductors to any great extent or all conductors would be hollow.

The primary reason that high-voltage outdoor busbars in substations are tubular is to provide them with mechanical strength.

If they were solid, and of equivalent cross-sectional area, then they would not be self-supporting to the same extent as tubes, and would require supports that are much closer together.


The 'skin effect', however, iscertainly taken into account when determining optimum diameter/thickness of these busbar tubes because the skin effect becomes more important with large-diameter conductors.


Indoor busbars, such as those found in metal-clad switchgear are indeed solid and, usually, of rectangular section, with supports that are much closer together than for outdoor, tubular, busbars.


Counter comment
At 60 Hz in copper, the skin depth is about 8.5 mm. Because the interior of a large conductor carries so little of the current, tubular conductors such as pipe can be used to save weight and cost.

2000MCM wire has resistance about 23% higher at 60Hz AC than DC

source NFPA bulletin 7 sometimes called NEC

for uk and sqMM and 50hz i have added a link


insignificant for someone who works for power companies is understandable
since fuel cost is insignificant it is passed right on to the customer
IR losses are insignificant also

this is why a 50KVA transformer on the pole supplies 7-10 houses with 200A services 4/0 copper into the house #2AL drops with #8 solid copper going to the poles that feed 7 of the 10 drops

power company is a misnomer in the USA it is a power DISTRIBUTION company
hence fuel cost is insignificant ir losses are insignificant.
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Q: What material is a bus bar made of?
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