Bus Bar Engineering Resources

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Welcome to Storm Power’s Bus Bar Resources. Listed below are bus bar design specifications on Insulation, Epoxy Powder Coating, Multilayer Laminated Conductors, Copper and Aluminum Ampacity Tables, Copper vs. Aluminum Performance Comparison, Flexible Bus Conductors, to name just a few of the subjects covered. Please don’t hesitate to give us a call at 800-394-4804, if you need assistance with an engineering question not covered in the pdf documents below.

4. BUS BAR PROFILE vs. CURRENT DENSITY SIZING GUIDE

The following chart shows the impact of changes in bus bar size to the overall current density of the conductor.

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Dimension, In. Area Weight Per Ft
in Lbs
Amperage DC Resistance
at 20° C
30° C Rise 50° C Rise 65° C Rise
Sq. In Circ Mils
Thousands
Amps/
Circ Mils
Amps
Per Sq. Ft.
Microhms
Per Sq. Ft.
Skin Effect
Ratio
at 90° C
60 Hz
Ampacity
Amp*
Skin Effect
Ratio
at 90° C
60 Hz
Ampacity
Amp*
Skin Effect
Ratio
at 90° C
60 Hz
Ampacity
Amp*
1/16 x 1/2 .0312 39.7 .121 385 3209 264.0 1.00 103 1.00 136 1.00 157
1/16 x 2 .125 159 .483 460 2760 65.8 1.01 345 1.01 460 1.01 530
1/8 x 1 .125 159 .483 589 2160 65.8 1.01 270 1.01 360 1.01 415
1/8 x 3 1/2 .438 558 1.69 688 1849 18.8 1.04 810 1.03 1100 1.03 1250
3/16 x 1 .188 239 .726 702 1808 43.8 1.01 340 1.01 455 1.01 520
3/16 x 3 .562 715 2.17 821 1548 14.6 1.05 870 1.05 1150 1.04 1350
1/4 x 3/4 .188 239 .726 746 1702 43.8 1.01 320 1.01 425 1.01 490
1/4 x 3 .750 955 2.90 965 1320 11.0 1.08 990 1.08 1300 1.07 1550
3/8 x 2 1/2 .938 1190 3.62 1133 1119 8.77 1.12 1050 1.10 1400 1.09 1600
1/2 x 1 1/2 .750 955 2.90 1150 1107 11.0 1.08 830 1.08 1100 1.07 1250
1/2 x 4 2.00 2550 7.73 1500 850 4.11 1.26 1700 1.25 2300 1.24 2650
1/2 x 10 5.00 4770 14.5 1998 640 1.65 1.48 3250 1.46 4800 1.44 3750
3/4 x 10 7.50 9550 7.73 2274 560 1.10 1.67 5600 1.64 5600 1.62 6500