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Busbars

Busbars

Total Connections has earned a well-deserved reputation as a supplier of heavy-duty busbars. We can design and manufacture bespoke busbars for any type of electrical installation - in a wide variety of sizes, configurations, materials, and finishes.

View a selection of our latest busbar design and manufacture projects below:

Busbars Labelled
Different Materials

Different Materials

Total Connections can offer the following types and finishes of busbars:

  • Solid busbars
  • Copper tube busbars
  • Flexible busbars (braided connectors)
  • Multi-layered busbars
  • Laminated busbars
  • Transformer busbars
  • Jumper leads

We manufacture busbars in a variety of materials:

  • Copper busbars (C101/C103/C106/C109)
  • Brass busbars
  • Bronze busbars
  • Stainless Steel busbars
  • Steel busbars
  • Monel busbars
  • Beryllium-Copper busbars
Different Finishes

Different Finishes

We manufacture busbars in a variety of finishes:

  • Natural/etched busbars
  • Bright/matt tin plate busbars
  • Copper plate busbars
  • Nickel plate busbars
  • Silver plate busbars
  • Gold plate busbars
  • Zinc plate busbars

We can provide other finishes upon request - for steel, Vibro-finished, sand/shot blasted and annealing.

For more information about our busbars, contact us today.

Busbar Design

When approached by customers with requirements for busbars, we are able to design the busbar using CAD software to determine exactly what is required in the manufacturing process.

This allows us to see the complexities of the required busbar and visualise exactly how it is going to look once it is manufactured. It gives the design engineers an opportunity to explore any challenges that the manufacturing process might face.

Bent Bar Cad 1

At this stage, a CAD design of the finished product can be produced.

At this stage, all of the elements in the design process come together. We can see the flat pattern that is required to form the finished profile, alongside a 3D representation of the finished busbar. Dimensions, hole centres and other essential elements can be checked before going to manufacture.

It can be shared with the customer to ensure that the design brief has been followed.

Bent Bar Cad 2

The software is able to take account of the bending and folding during manufacture and calculate the straight bar length required, as well as the exact position of the bend/fold points.

Dimensions will change during the folding/bending process and the software is designed to take this into account. It is important that we start with the right size of material, so that the finished product is correct and in accordance with the desired dimensions.

Our CNC machines can then be programmed to manufacture the finished shape, prior to any finishes that the busbar requires.

Bent Bar Cad 3

Busbar Manufacturing Capabilities

Total Connections has invested in the latest state-of-the-art CNC punching, forming, and insertion machines. They have helped to automate much of what we do in the manufacture of busbars.

As a company, we are capable of the manufacture of very heavy-duty switchgear busbars and earthing products - including busbars up to 3.5m in length. For more information about our capabilities, visit our capabilities web page.

Machine 1
Machine 2
Machine 3

Why buy Busbars from Total Connections?

Agile

  • Fast & Effective
  • Integrated Design & Manufacture

Unlike some of our competitors, we do not separate out design from manufacture.

To remain agile, and to provide for fast and effective turnaround, our integrated in-house design and manufacture team sees each project through from scoping, design using 3D CAD, rapid-prototyping (where applicable), through to manufacture and dispatch.

Quality

  • Quality Materials
  • Quality Finishes

We have many years of experience in design and manufacture and we have a growing reputation to safeguard. We use a wide variety of the finest materials according to our customer's requirements.

In common with our other products, we can provide a wide variety of finishes. Our busbars are designed and manufactured for reliability and longevity of use.

Competitive

  • Competitive Pricing
  • Quantity Pricing

We have captured an ever-growing slice of the market by being a quality supplier of busbars and switchgear, whilst doing so at competitive prices.

We provide competitive individual unit pricing through to quantity-dependent pricing suitable for large-scale projects and tenders. We price to reduce your need to shop around - your one-stop busbar supplier.