WHITEPAPER

MATERIALS FOR ELECTRIC BUSWAYS

David Chapman, Bruno De Wachter, Stefan Fassbinder

August 2012

ECI Publication No Cu0103

Available from www.leonardo-energy.org/node/156461

Document Issue Control Sheet

Document Title: White Paper Materials for Electric Busways

Publication No: Cu0103

Issue: 01_bis

Release: August 2012

Author(s): David Chapman, Bruno De Wachter, Stefan Fassbinder

Reviewer(s): David Chapman, Hans De Keulenaer, Stefan Fassbinder, Hilton

Moreno, Rodolfo di Stefano

Document History

Issue Date Purpose Prepared Approved

1 06/07/2011 Initial publication

2 30/03/2012 Version 1_bis: addition of the new

Copper Alliance logo

Disclaimer
While this publication has been prepared with care, European Copper Institute and other contributors provide
no warranty with regards to the content and shall not be liable for any direct, incidental or consequential
damages that may result from the use of the information or the data contained.

Copyright European Copper Institute.

Reproduction is authorised providing the material is unabridged and the source is acknowledged.

Publication No Cu0103 Page i

Issue Date: August 2012
CONTENTS
Summary: Numerous reasons to choose copper 1

Copper busways more compact and/or more energy efficient2

Taking harmonics into account 2

Easy, efficient, and durable connections 3

Resisting aggressive environments 3

Resisting mechanical forces of short circuit currents 4

Taking all cost aspects into account 4

Round up 5

Publication No Cu0103 Page ii

Issue Date: August 2012
SUMMARY: NUMEROUS REASONS TO CHOOSE COPPER

Busbars, busducts, and busways using copper conductors have several advantages compared to their
counterparts fabricated from other materials.

The main advantages of copper arise from its high electric conductivity (low electric resistance). These
characteristics make it possible to create busways with the same current carrying capacity but that are smaller
and/or more energy efficient.

In addition, the use of copper results in highly durable connections that can resist strong mechanical forces.

Cost of the conductor should not be the only consideration when evaluating the cost of a busway. The cost of
the mechanical support systems, the energy losses over the lifetime of the installation, and the scrap value of
the material at its end-of-life must all be taken into consideration in order to gain an accurate picture. When
this is done, it becomes clear that the initial price of copper has only a minor influence on the total life cycle
cost of the busway.

Publication No 0102 Page 1

Issue Date: July 2011
COPPER BUSWAYS MORE COMPACT AND/OR MORE ENERGY EFFICIENT
Copper has a conductivity of 58 MS/m (at 20 C), which is the second highest conductivity to be found in nature
(after silver). The conductivity of aluminium is 35 MS/m (at 20 C), or approximately 60% that of copper.

The high conductivity of copper can be used to advantage in two situations:

1) A copper busway has a higher energy efficiency than an aluminium counterpart of the same width.
This brings with it the obvious financial and environmental benefits, such as reduced energy costs and
reduced CO2 emissions. Higher conductivity also reduces the voltage drop on the busway, which has a
positive influence on the reliability of electrical appliances in the network. Furthermore, higher energy
efficiency means less loss through heat dissipation, allowing busways to be installed closer to one
another.
2) When the energy efficiency of a copper busway is identical to that of its aluminium counterpart, the
copper busway will have a smaller cross section. This compactness adds several advantages:
i. Less space required for support mechanisms and for the structures housing the
busway. These structures will also be less expensive.
ii. No additional labour and handling effort is required to install a copper busway
because of its higher weight, as this is compensated by its smaller size and the
smaller size of its supporting structures.
It is also possible to achieve both the energy efficiency and compactness advantages to a lesser degree.

TAKING HARMONICS INTO ACCOUNT

The connection of non-linear single-phase loads will result in harmonic currents flowing through the neutral
and phase busways. In this event, the width of both phase and neutral busways has to be upgraded by the
following factors:

Non-linear load/linear load Upgrading factor

0.00 1.000
1.00 1.155
1.25 1.233
1.50 1.323
1.75 1.422
2.00 1.527
Source: GE Energy Industrial Solutions,
brochure on Spectra SeriesTM Busway

The busway will have to be wider in order not to compromise on voltage drop, heat dissipation, and energy
efficiency.

As a result, the differencein absolute valuebetween the minimum width for aluminium busways and that
of their copper counterparts becomes even larger.

Publication No 0102 Page 2

Issue Date: July 2011
If the width of an aluminium busway was calculated without taking non-linear loads into account, one way to
incorporate the de-rating factor of non-linear loads in a later phase of the project is to switch from aluminium
to copper, keeping the same busway width.

EASY, EFFICIENT, AND DURABLE CONNECTIONS

A busway made out of copper is smaller than its aluminium counterpart with a similar current carrying
capacity. The same is true of busway connection systems. Its compact size makes the installation of a copper
busway and the addition of new connections easy and convenient. In the case of an interior system where
space is limited, the use of copper will often be crucial to the design of the installation. A copper busway will
sometimes enable an additional connection where a complete new installation elsewhere in the building would
otherwise be required.

Copper busways are not only easy to install, they also last for a long time. Connections to a copper busway can
withstand temperature cycles caused by load variations without significant degradation. Forces are evenly
distributed at the joint of a copper cable to a copper busway. This results in low energy losses, low temperature
variances, and a durable connection. This contrasts with aluminium and most of its alloys. Aluminium
connections deteriorate over a number of load cycles due to loss of contact force.

RESISTING AGGRESSIVE ENVIRONMENTS

Busways that are used in aggressive chemical environments of industrial production sites will be subject to
accelerated corrosion. The use of copper as a conductor is the only guarantee that corrosion will remain limited
and will not affect the electrical properties, energy efficiency, and mechanical strength of the busway.

Publication No 0102 Page 3

Issue Date: July 2011
RESISTING MECHANICAL FORCES OF SHORT CIRCUIT CURRENTS
In the event of a short circuit, a high current will flow inside the busway before a circuit breaker cuts it. Those
currents bring along high tensile forces that risk the complete destruction of the installation. In a sandwich type
busway, those forces are restrained by the housing structure. However, in other types of busways, it is the
conductor material itself that should be strong enough to withstand it.

Half-hard copper has a tensile strength of 260 up to 300 N/mm 2. The value for annealed copper is slightly
lower, ranging between 200 and 250 N/mm 2. The tensile strength of aluminium only ranges between 50 and
100 N/mm2.

Consequently, the copper version will withstand higher short circuit currents when the same mechanical
support systems are used for a copper busway as for its aluminium counterpart.

Likewise, if an aluminium busway has to withstand similar short circuit currents as its copper counterpart, it
requires more and stronger mechanical support systems, driving up the total cost of the installation.

TAKING ALL COST ASPECTS INTO ACCOUNT

When comparing the cost of different busway materials, it is not just the investment cost that needs to be
taken into account. All of the various cost factors over the complete economic life cycle of the system,
recalculated to present time values must be considered. These factors include:

Energy losses: The cost of energy losses depends upon the load on the busway and the electricity
tariff for a given rated current and busway material conductivity. The high conductivity of copper will
result in low energy losses. Note that a more precise calculation of these losses requires using the load
and electricity tariff at each moment in time, rather than averages. As high loads tend to happen
during moments of peak tariff, such a calculation will reveal a higher annual cost of energy losses.
The cost of support materials, surrounding structures, and busway connections: The wider the
busway, the more expensive these systems will be.
Scrap value: One of the most intriguing aspects of copper is that it is a 100% recyclable material with a
high scrap value at the end of life of the busway. The market prices of all electrical grade copper scrap
are close to the prices of new copper.

Publication No 0102 Page 4

Issue Date: July 2011
ROUND UP
When choosing the conductor material for a busway or busbar, the cost over the complete life cycle of the
system must be taken into account, as well as a few critical technical aspects.

A copper busway will be smaller and/or more efficient than its aluminium counterpart. The reduced width
makes the copper busway easier to install and reduces the size and cost of supporting structures. Higher
energy efficiency brings obvious financial and environmental advantages. These advantages become even more
pronounced when non-linear loads are expected, requiring an upgrade of the busway width. A calculation of
the life cycle cost should also take into account the scrap value of the material at the system end-of-life. Market
prices for electrical grade copper scrap are usually high and close to the value of new copper.

The use of copper as a busway material has additional advantages. Connections of copper cables to copper
busways are durable, withstanding load and temperature cycles. A copper conductor can also withstand
aggressive industrial environments without excessive corrosion. And last but not least, the tensile strength of
copper is high, making it able to withstand the high mechanical forces caused by short circuit currents.

Publication No 0102 Page 5

Issue Date: July 2011