Different Types of Aluminum Bus Bars and Their Applications

Aluminum bus bars, also known as power bars or busways, are essential components in many electrical systems. These conductors act as a common connection point for various circuits, distributing electricity to multiple devices. This post will explore the different types of aluminium bus bars and their respective applications.

What is Aluminum Bus Bars?

Aluminium bus bars are electrical conductors typically made from aluminium and used for power distribution in various industrial, commercial, and residential settings. They provide a low-cost, lightweight option for conducting large amounts of current with minimal voltage drop. Depending on the application, bus bars can take various shapes, such as flat sheets, round rods, extruded tubes, or angles. Features like weatherproofing and shielding help protect them from heat and corrosion. For maximum efficiency, they should be fully insulated to prevent short circuits.

Types of Aluminum Bus Bars

Solid Bus Bars

Solid bus bars are electrical connections composed of metal conductor bars, typically copper or aluminium. They are commonly used to distribute power in installations with high current ratings. The advantages they provide include improved reliability, easier installation and maintenance, decreased resistance due to higher cross-sectional area, and lower electromagnetic interference.

Solid bus bars are made from a single piece of aluminium and are ideal for high-power systems. These bars are sturdy and can handle high currents, making them suitable for industrial applications. Solid bus bars can handle continuous currents of up to 400A and may be used in switchgear, transformers, and other power distribution systems.

Hollow Bus Bars

Hollow bus bars are cylindrical and have a hollow core, which makes them an excellent choice for applications where lightness and flexibility are needed. These bars, commonly used in high-current applications, such as motor control centres, can handle continuous currents of up to 200A. They also require less material than solid bus bars, making them a more cost-effective option.

Hollow Bus Bars are electrical conductors that provide a simple, cost-efficient solution to distributing large amounts of electrical current. They are often used in traction systems, telecommunications networks and lift installations. Their hollow shape reduces storing and installation costs compared with traditional solid bus bars.

Insulated Bus Bars

Insulated bus bars have an insulating layer, making them safe for high-voltage applications. These bars are typically coated with an insulating material such as epoxy or PVC, which helps prevent electrical arcing. Insulated bus bars can handle currents of up to 1200A and are commonly used in power distribution centres, substations, and switchboards.

Flexible Bus Bars

Flexible bus bars are made from multiple strands of aluminium wire braided and insulated together. These flexible bars can be bent, twisted, or wrapped around corners, making them an ideal choice for applications requiring precision and flexibility. They can handle continuous currents of up to 225A and are commonly used in high-end automotive applications, data centres, and power generation units.

Laminated Bus Bars

Laminated Bus Bars are made from layers of aluminium or copper, which are then laminated together. This construction gives laminated bus bars high inductance and resistance to electrostatic interference. These bars are typically used in applications requiring compactness and high conductivity, such as in hybrid electric vehicles, wind turbines, and solar inverters. Laminated Bus Bars can handle continuous currents of up to 1500A.


Aluminium bus bars have become a critical component in the modern electrical system. As technology advances, the demand for more efficient and reliable electrical power distribution systems continues to grow. Understanding the different types of aluminium bus bars and their respective applications can help select the right ones for specific applications. Always choose a bus bar that can handle the required current and is compatible with the system’s voltage. Also, ensure that you follow the manufacturer’s guidelines when installing them to ensure long-term performance.