Cost-Effectiveness and Sustainability

One of the most compelling arguments for aluminum busbars is their cost-effectiveness. Aluminum is significantly lighter than copper, reducing material costs and making it an attractive option for budget-conscious projects¹. Aluminum at the time of writing, costs USD 2.66/KG and Copper USD 9.86/KG, aluminum stands currently to be 3.7 times cheaper than copper and is why is often considered as an alternative to copper. In electrical busbar systems, the dimensions of each segment differs from every project, however, aluminum is typically weighed less per meter in comparison to copper further saving on prices. Moreover, aluminum's recyclability adds an eco-friendly aspect, which follows suit with Fliton’s Green Mission, where we progress as the world’s first eco-friendly busbar manufacturer (Learn more about our mission here).

Conductivity and Efficiency

Copper busbars has a conductivity rating of up to 99.8% IACS (International Annealed Copper Standard), Aluminum busbars, exhibit around 62% IACS. This figure is often misinterpreted as aluminum being simply a less viable option. In actuality, to ensure the voltage and amp requirements are met we can simply enlarge the aluminum busbar conductors. Even with a larger diameter leading to additional insulation material and material it would still be cheaper and lighter than it’s copper counterpart.

Thermal Properties

Thermal management is essential in busbar design. The material Copper's thermal conductivity is 401 W/m·K, and Aluminum's thermal conductivity is 237 W/m·K. While its heat dissapating ability is lower, the evaluation of temperature ranges is different with our fully insulated tubular busbars. To dispel the misconceptions and concerns in the use of aluminum conductors, and our answer is innovation. At Fliton we ensure temperature regulation through the use of thicker insulation layers or by implementing a cooling system. All of which again still would be a cheaper alternative than copper busbars.

Installation and Application

The real difference between the two materials lies in the handling of installation. While in general our busbars are easy to install, copper busbars are typically thinner and easier to fit which can save time and labor costs. Aluminum busbars are however a bit wider for the same operating standard but still significantly lighter, making them easier to handle, saving on labour effort and installation time. The application of the two materials differs in facility types and space. Copper is more dense but more compact while aluminum (in the same operating requirement) is lighter but larger. Depending on your facility we may suggest one type over the other regardless of cost, ensuring that you are informed of the best possible solution.

Choosing the Right Material for Your Project

At Fliton we provide multiple solutions with multiple insulation material and conductor material and provide informed decision making for all clients. Selecting the appropriate busbar material depends on various factors, including electrical requirements, mechanical strength, thermal performance, cost, and environmental impact. Copper busbars may be the go-to for high-demand applications, while aluminum busbars can provide a cost-effective and lightweight solution without compromising performance.