Copper vs Aluminum Busbar - Which is right for your project?

06 May.,2024

 

Copper vs Aluminum Busbar - Which is right for your project?

When considered on a percentage basis, aluminum is the most recycled industrial metal with 75% of aluminum ever produced still in use today. For copper, this number is 65%. Similarly, the recycling process for aluminum uses only 5% of the energy required for primary production and releases only 5% of the associated emissions. Again, although copper can also be recycled at a reduced environmental cost, the process is different, using 15% of the energy required to mine and extract the same copper. With this in mind, aluminum is arguably a more sustainable option for busbar trunking conductors as it is less reliant on non-eco mining and extraction processes and can its recycling processes produce less energy waste.

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What are the advantages of a copper bus over ...

The #1 use is to avoid hypocrisy. It looks dumb to insist on copper wire, and then, buy the cheapest panel and not realize it has aluminum buses. (as well as aluminum lugs).

The lugs are aluminum for a very good reason - due to thermal expansion differences, this plays to aluminum's advantage, making it the "universal donor". Copper lugs play badly with aluminum wire (hence the famous trouble with That 70's small branch circuit wiring).

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However the bus bars can go either way. One thing for sure - when things fail, we see a lot of reports of it on here. I don't see too many bus stab failures that have no other reason to have happened. Lots due to alien breakers, some due to misfit (the breaker wouldn't seat all the way because of an alien breaker next to it, user pushing the breaker off the stab to make the wrong cover fit, etc.)

One case where I would stick to copper is a panel that lives in rough conditions like outdoors. The tin plating can be exhausted, and aluminum would corrode with pitting - just what you don't want on a bus stab. Copper does not corrode easily - in fact, it's one of only a few metals found in nature in its metallic form (i.e. 4 billion years and it never oxidized).

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