Flexible Busbars for Switchgear
Reliable high-current connections for switchgear, transformers, and power distribution equipment - rated 100 A to 10,000 A and up to 36 kV. Our flexible copper busbars compensate for thermal expansion and vibration while maintaining the electrical performance of solid copper.
Key Features
Thermal Expansion Compensation
Absorbs dimensional changes caused by heating during high-current operation, preventing stress on terminals, bushings, and insulators.
Vibration Isolation
Flexible construction isolates vibrations from breakers, transformers, and rotating machinery, preventing fatigue failures and loosening of bolted connections.
Misalignment Tolerance
Accommodates manufacturing tolerances and installation variations between connection points - no precision alignment needed.
Easy Installation
Bends around obstacles and simplifies installation in confined panels, reducing assembly time compared to rigid bars that need exact pre-forming.
Why Use Flexible Busbars in Switchgear?
In switchgear and transformer applications, electrical connections must carry high currents while accommodating mechanical stresses. Rigid busbars transmit these stresses directly to insulators, bushings, and terminals, loosening bolted joints and cracking ceramic components over years of thermal cycling.
Flexible busbars act as stress-relief elements, absorbing thermal expansion, contraction, and vibration. This protects sensitive equipment, keeps contact resistance stable, and extends the service life of the entire installation.
The laminated construction also provides lower inductance than solid conductors of the same cross-section - beneficial in circuits with high switching frequencies or transient currents.
Common Applications
- Low and medium voltage switchgear
- Power and distribution transformers
- Circuit breaker connections
- Disconnect switch links
- Bus duct and busway systems
- Generator and alternator connections
- Capacitor bank connections
- Reactor and rectifier connections
Technical Specifications
| Current Rating | 100 A - 10,000 A |
| Voltage Class | Up to 36 kV |
| Conductor Material | ETP Copper (99.9%+ purity) |
| Lamination Thickness | 0.1 - 0.3 mm |
| Insulation Class | Class B, F, or H |
| Temperature Range | -40°C to +150°C |
| Terminal Options | Drilled holes, palm terminals, custom |
| Surface Treatment | Bare, tin-plated, silver-plated |
Need help selecting a cross-section? See our flexible busbar sizing & ampacity guide.
Design Considerations
Current Capacity
- Cross-sectional area determines ampacity
- Number and thickness of laminations
- Operating temperature limits
- Duty cycle considerations
Mechanical Requirements
- Expected thermal movement range
- Vibration frequency and amplitude
- Installation space constraints
- Terminal orientation and spacing
Environmental Factors
- Indoor or outdoor installation
- Humidity and corrosion resistance
- Altitude and air density
- Contamination and pollution levels
Insulation Options
PVC Sleeving
Up to 105°C
Cost-effective general purpose insulation
Heat Shrink
Up to 125°C
Tight-fitting moisture-resistant covering
Kapton Film
Up to 200°C
High-temperature polyimide insulation
Silicone Rubber
Up to 180°C
Flexible high-temperature insulation
Switchgear Busbar FAQ
Why are flexible busbars used in switchgear?
Switchgear connections carry high currents that heat conductors and cause thermal expansion. A rigid connection transmits this expansion force directly into bushings, insulators, and terminals, loosening joints and cracking ceramics over time. A flexible busbar absorbs that movement, plus vibration from breakers and transformers, protecting the equipment and extending service life.
What voltage class can flexible busbars handle?
The copper conductor itself is voltage-independent - voltage capability is determined by insulation, creepage, and clearance. SVS Maverick supplies flexible busbars for low-voltage assemblies and medium-voltage switchgear up to 36 kV, with insulation classes B, F, or H as the design requires.
Can you replace a rigid copper link with a flexible busbar?
Yes, in most cases. A flexible busbar with the same copper cross-section carries the same current as the rigid bar it replaces, while adding thermal-expansion compensation and vibration isolation. Send us the drawing of the existing link and we will quote a direct flexible replacement.
What plating do you recommend for switchgear connections?
Tin plating is the standard recommendation for switchgear: it prevents oxidation at bolted joints and maintains low contact resistance for decades. Silver plating offers the lowest contact resistance for very high current or frequently operated connections. Bare copper is acceptable in dry, indoor, regularly maintained installations.
Related Products & Guides
Need Custom Switchgear Busbars?
Send us your specifications or drawings for a custom quotation. Our engineering team manufactures flexible busbars in Bangalore, India for switchgear OEMs and panel builders in India and worldwide.
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