Reliable Insulation for Copper and Aluminium Busbars
Busbar tubing provides a heat-shrinkable insulation system for copper and aluminium busbars in switchgear, distribution panels, substations, and industrial power assemblies. By enclosing the busbar in a recovered insulation layer, the tubing eliminates exposed live surfaces, prevents flashover between adjacent busbars and grounded structures, and significantly reduces the risk of accidental electrical contact during installation and maintenance operations.
Compatible with both rectangular and round busbar profiles, the large-diameter tubing range accommodates standard busbar cross-sections. Colour-coded variants support phase identification in three-phase systems without additional marking or labelling.
- Material Crosslinked Polyolefin
- Shrink ratio 3:1 minimum
- Min. shrink temperature 120°C
- Tracking resistance Yes — IEC 60587
- Flame retardant Yes — IEC 60332-1
- Standard colours Red, Yellow, Blue, Black
- Operating temperature –55°C to +125°C
Why Busbar Tubing Is Specified
Purpose-designed for busbar insulation in high-density electrical assemblies where safe clearance distances and phase identification are engineering priorities.
Enhanced Insulation Against Flashover
Fully enclosing the busbar in recovered tubing eliminates exposed live surfaces and prevents flashover between adjacent busbars, enclosures, and grounded structures — a critical requirement in high-density switchgear and panel assemblies with reduced phase clearances.
High Tracking and Arc Resistance
The compound formulation provides resistance to surface tracking and arc damage — maintaining insulation integrity under conditions of contamination, condensation, or transient overvoltage in enclosed switchgear environments.
Compatible with Rectangular and Round Profiles
The 3:1 shrink ratio and large-diameter size range accommodate both rectangular flat busbars and round bar conductors — a single product range covering the full scope of standard busbar cross-sections without profile-specific variants.
Flame-Retardant Properties
Compliant with IEC 60332-1 for flame retardance — preventing flame propagation along the busbar run in the event of a fault condition, a mandatory requirement for enclosed switchgear and panel installations.
UV and Environmental Resistance
UV-stabilised formulation maintains insulation performance in outdoor substations and exposed installations — suitable for above-ground busbar runs subject to weather, humidity, and temperature cycling.
Mechanical Durability
Recovered busbar tubing provides abrasion and impact resistance over the busbar surface — protecting against mechanical damage during panel assembly, conductor routing, and service maintenance operations.
Material & Performance Data
Reference data for engineering and procurement. Contact our technical team for full test reports or project-specific qualification data.
| Base material | Irradiation-crosslinked polyolefin |
|---|---|
| Standard colours | Red, Yellow, Blue, Black — for phase identification and general insulation |
| Shrink ratio | 3:1 minimum |
| Min. shrink temperature | 120°C |
| Operating temperature | –55°C to +125°C (continuous service) |
| Tracking resistance | Yes — tested to IEC 60587 |
| Flame retardant | Yes — compliant with IEC 60332-1 |
| Halogen-free | Yes |
| UV / weather resistance | Yes — suitable for outdoor and exposed busbar installations |
| Installation method | Hot air gun — applied along the busbar length with progressive heat movement |
| Shelf life | 10 years from manufacture date when stored per IEC 60684 storage guidelines |
| Applicable standards | IEC 60684 (heat-shrinkable tubing), IEC 60587 (tracking resistance), IEC 60332-1 (flame retardance) |
Where Busbar Tubing Is Used
Applied wherever bare copper or aluminium busbars require electrical insulation, phase identification, or protection against flashover and accidental contact.
Switchgear Insulation
Applied over busbar conductors within LV and MV switchgear assemblies to insulate live busbars, reduce required clearance distances, and prevent flashover in high-density enclosure layouts.
Substation Systems
Used on exposed busbar runs in indoor and outdoor substations — providing insulation, weather resistance, and colour-coded phase identification for distribution and transmission busbars.
Panel Board Connections
Insulates main busbars and distribution bars in LV distribution boards, motor control centres, and industrial panel assemblies — supporting safe working conditions and reducing accidental contact risk during maintenance.
Transformer Connections
Applied to busbar connections at transformer LV terminals to insulate and protect exposed conductors at the transformer-to-panel interface in utility and industrial power systems.
Industrial and Utility Power Systems
Specified across industrial facilities, utility infrastructure, and EPC projects wherever busbar insulation, phase identification, and flashover prevention are installation requirements.
Indoor and Outdoor Installations
UV-stabilised and weather-resistant formulation supports both enclosed indoor installations and exposed outdoor busbar runs — maintaining insulation performance across varied service environments.
How to Select the Right Busbar Tubing
Six criteria determine the correct size and specification. Work through each before ordering to ensure the tubing is correctly matched to the busbar dimensions and application requirements.
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01
Busbar Profile
Confirm whether the busbar is rectangular (flat bar) or round (circular section). Rectangular busbars require the tubing supplied diameter to accommodate the diagonal dimension of the cross-section — not just the flat face width — to allow the tubing to be positioned over the bar before heat application.
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02
Busbar Dimensions
For rectangular busbars, measure the width and thickness of the cross-section and calculate the diagonal (√(W² + T²)) — this is the minimum supplied inner diameter required for the tubing to pass over the bar. For round busbars, measure the outer diameter directly. Select the tubing size whose supplied diameter exceeds this value and whose recovered diameter is smaller than it.
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03
Voltage Class
Confirm the system voltage of the busbar installation. Busbar tubing is suitable for LV applications in standard configurations. For MV busbar insulation requirements, confirm the voltage class with our technical team to ensure the selected product provides adequate dielectric strength for the service voltage.
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04
Insulation Thickness
The recovered wall thickness determines the insulation level provided. Confirm the insulation thickness requirement from the switchgear or panel design specification. Where the specification requires a minimum wall thickness after recovery, verify this against the product data for the selected tubing size before ordering.
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05
Indoor or Outdoor Installation
Both indoor and outdoor applications are supported. For outdoor busbar installations subject to direct UV exposure, weather, or condensation — confirm that the selected colour and product variant includes UV stabilisation. Black is generally preferred for outdoor applications due to superior UV resistance; phase colours are typically used for indoor phase identification.
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06
Colour for Phase Identification
Busbar tubing is available in red, yellow, blue, and black. For three-phase systems, specify red, yellow, and blue for L1, L2, and L3 phase identification respectively — consistent with standard electrical installation colour-coding practice. Confirm the colour scheme with the project specification before ordering as phase colour conventions may vary by project standard.
For rectangular busbar sizing calculations or MV busbar insulation requirements, contact our technical team before finalising the specification.
Common Technical Questions
For a rectangular busbar, the tubing must fit over the bar before shrinking. The relevant dimension is not the flat face width but the diagonal of the cross-section — calculated as the square root of (width squared plus thickness squared). For example, a 50mm × 6mm busbar has a diagonal of approximately 50.4mm. The tubing supplied inner diameter must exceed this value to allow positioning over the bar. After recovery, the tubing should conform tightly to the flat faces and corners of the cross-section. Contact our technical team for a sizing confirmation if the calculation is uncertain.
Standard tubular busbar tubing must be threaded over the busbar end before the bar is fixed — it cannot be applied radially to an installed busbar. If the busbar is already fixed in position and cannot be removed, wraparound sleeve products are the appropriate alternative, as these can be applied laterally and sealed without requiring access to the busbar end. Western Cablex wraparound sleeves are available for this application — contact our technical team for details.
Busbar tubing is available in red, yellow, blue, and black. Colour is achieved through pigmentation of the base compound and does not alter the fundamental electrical or mechanical properties of the product — all colours share the same material specification, shrink ratio, and operating temperature range. Black provides the highest UV resistance and is preferred for outdoor applications. Phase colours (red, yellow, blue) are primarily used for indoor phase identification in switchgear and panel assemblies.
Yes. Busbar tubing is compatible with both copper and aluminium busbar conductors. The recovered tubing contacts the outer surface of the bar — no chemical bonding between the tubing and the conductor is required, and the crosslinked polyolefin compound is chemically inert with respect to both metals. Ensure the busbar surface is clean and free of burrs before applying the tubing to achieve a smooth, void-free recovery.
A hot air gun is recommended for busbar tubing installation. Begin heat application at one end of the tubing length and move progressively along the busbar — this allows air to escape from the open end and prevents air entrapment beneath the recovered material. Maintain a consistent distance and movement speed to achieve uniform recovery along the full length. For rectangular busbars, give additional attention to the corners of the cross-section to ensure full corner recovery. The minimum shrink temperature is 120°C — ensure the tubing surface reaches this temperature uniformly.
Busbar tubing is supplied in large-diameter sizes covering standard busbar cross-sections from small panel busbars through to larger distribution busbar dimensions. It is available in standard lengths and can also be supplied in project-specific cut lengths for panel assembly applications. Specify the busbar cross-section dimensions when enquiring — our technical team will confirm the correct size, available lengths, and lead time for the required colours and quantities.
Need Help Selecting the Right Busbar Tubing?
Speak with our technical team for sizing, application guidance, and product recommendations.