What Are Busbar Supports? Types, Applications, and Selection Guide
In modern electrical power distribution systems, busbars play a critical role in carrying and distributing large amounts of current safely and efficiently. However, to ensure their reliability and safety, busbars need proper mechanical and electrical support. This is where busbar supports come into the picture.
In this guide, we’ll explore what busbar supports are, their types, applications, and how to select the right one for your electrical system.
What Are Busbar Supports?
Busbar supports are mechanical components designed to hold and insulate busbars in electrical systems such as switchgear, control panels, and power distribution boards. Their main function is to:
- Provide mechanical strength to hold the busbars in place
- Ensure electrical insulation between conductors and ground
- Withstand thermal and dynamic forces during short circuits
- Maintain safe clearance between busbars to prevent flashovers
Without proper busbar support, the busbar system may face mechanical stress, overheating, or even dangerous faults during high current conditions.
Types of Busbar Supports
There are different types of busbar supports available, depending on the voltage level, material, and application. Let’s look at the most common ones:
1. Porcelain Busbar Supports
- Made from high-strength porcelain
- Excellent thermal resistance
- Commonly used in high voltage busbar supports
- Very durable, but relatively heavy
2. Epoxy Busbar Supports
- High mechanical strength and short circuit withstand capacity
- Provide better insulation than porcelain
- Widely used in low voltage busbar supports and switchgear components
3. Polyamide Busbar Supports
- Lightweight and cost-effective
- Good insulation and electrical safety
- Suitable for control panels and low current applications
4. Composite and Customized Busbar Supports
- Combination of different insulating materials
- Designed for specific applications
- Useful in environments where high temperature or corrosive conditions exist
Applications of Busbar Supports
Busbar supports are used across various sectors of power distribution and electrical systems. Some of the key applications of busbar supports include:
Switchgear and Control Panels – To ensure busbars remain stable under load and fault conditions
- Power Distribution Boards – For safe separation and insulation of multiple conductors
- Industrial Electrical Systems – Used in manufacturing plants, data centers, and process industries
- Low and High Voltage Applications – Different support materials (epoxy, porcelain, polyamide) are selected depending on the voltage rating
- Renewable Energy Systems – Inverters, solar power plants, and wind turbine panels
By maintaining busbar safety and insulation, supports help prevent electrical hazards, ensure system reliability, and extend the lifespan of switchgear.
How to Choose the Right Busbar Support? (Selection Guide)
Selecting the right busbar support is crucial for safety, durability, and performance. Here are some key factors to consider when selecting busbar supports:
1. Voltage Level
- Low voltage busbar supports → Polyamide or epoxy types are preferred.
- High voltage busbar supports → Porcelain or epoxy with high insulation strength are recommended.
2. Short Circuit Withstand Capacity
Supports must handle the dynamic and thermal forces generated during short circuits without failure.
3. Material Type
- Porcelain – High mechanical strength, best for outdoor and HV systems
- Epoxy resin – Lightweight, durable, and excellent insulation for LV & MV switchgear
- Polyamide – Cost-effective solution for panels and low current systems
4. Environmental Conditions
If the system is exposed to moisture, dust, heat, or chemicals, choose epoxy or composite busbar supports that resist environmental stress.
5. Mechanical Strength
Busbar supports should be able to carry the weight of conductors while maintaining proper spacing.
6. Design and Mounting
Some systems may require customized busbar mounting supports to fit unique switchgear or enclosure designs.
Epoxy vs. Porcelain Busbar Supports: Which One Should You Choose?
One common debate is between epoxy busbar supports and porcelain busbar supports. Let’s make a quick comparison:
| Feature | Epoxy Supports | Porcelain Supports |
| Weight | Lightweight | Heavy |
| Strength | High mechanical & insulation strength | Very strong but brittle |
| Applications | Low & Medium Voltage | High Voltage |
| Cost | Moderate | Higher |
| Resistance | Better resistance to moisture & chemicals | Excellent thermal resistance |
If you are dealing with LV or MV switchgear, epoxy busbar supports are ideal. For HV outdoor applications, porcelain remains a reliable choice.
Benefits of Using the Right Busbar Support
Using the correct type of busbar insulation supports ensures:
- Improved system safety by preventing electrical faults
- Extended lifespan of switchgear and panels
- Better performance under short circuit conditions
- Reliable power distribution in industrial and commercial systems
In conclusion, Busbar supports may seem like small components in electrical systems, but they play a vital role in ensuring safety, reliability, and efficiency. From porcelain busbar supports in high voltage systems to epoxy and polyamide supports in low voltage applications, the right choice depends on your system requirements, environment, and voltage level. When selecting, always consider factors like short circuit withstand capacity, material type, and design requirements. By doing so, you ensure your busbar system remains secure and efficient for years.