Busbar systems: flexible and efficient power distribution

Busbar systems—also known as busway systems or power rails—offer an efficient, safe, and flexible solution for electrical power distribution. Particularly in environments requiring reliable distribution of high power loads, busbar systems serve as an attractive alternative to traditional cabling.

Elektro Internationaal has a dedicated project department specializing in busbar systems. Drawing on this expertise, we assist clients in designing and implementing complete power distribution solutions. Our approach focuses not only on the busbar system itself but also on its optimal integration with electrical distribution systems.

Busbar systems are widely used in industrial facilities, utility buildings, and data centers. Their modular design allows tap-off points to be strategically distributed along the route and enables relatively easy system modifications in response to changing power requirements or layout adjustments. This makes busbar systems particularly well-suited for environments where flexibility, availability, and scalability are key priorities.

Advantages of busbar systems over cables

Depending on the application, a busbar trunking system can offer significant advantages over a conventional cable installation:

• Modular and scalable – the system can be tailored to current power requirements and allows for future expansion.
• Flexible tap-offs – tap-off units can be installed, relocated, or added at predetermined positions, depending on the chosen system.
• Rapid installation – prefabricated sections and connections can significantly reduce on-site installation time and labor requirements.
• Compact power distribution – high power loads can be transmitted without bulky cable bundles, allowing for more efficient use of valuable space.
• Organized installation – the fixed busbar route ensures a structured and orderly power infrastructure.
• No large cable bending radii – busbar trunking can be routed through the building or technical room using appropriate elbow and angle elements.
• Suitable for high power loads – busbar trunking is ideally suited for the efficient distribution of high currents over long distances.
• Fire-safe design – compared to bulky cable bundles, the use of busbar trunking can significantly reduce the amount of combustible insulation material.
• Favorable electromagnetic properties – the compact arrangement of conductors helps limit electromagnetic fields.
• Sustainable material choice – busbar trunking consists largely of metals such as copper, aluminum, and steel, which are highly recyclable at the end of their service life.
• Easier adaptation to changes – power distribution can be modified more easily in response to changes in machine layout, production line expansion, or data center reconfiguration compared to many traditional cable installations.

From engineering to complete busbar system 

A successful busbar system begins with engineering. Factors such as power rating, load, selectivity, short-circuit withstand capability, environmental conditions, routing, tap-off points, and future expansions collectively determine the most suitable configuration.

Our specialized project department provides support with the design, engineering, and selection of the busbar system. Elektro-Internationaal can implement busbar systems from various manufacturers, depending on the project's technical requirements and specifications. Metering, as well as client- or project-specific measurement and billing systems, can also be incorporated into the solution.

By integrating the busbar system into the power distribution design from the outset, a unified, integrated system is created—extending from the main distribution and sub-distribution levels right through to the actual connection point at the load.

Busbar trunking and distribution systems optimally aligned

The combination of Power Distribution Units (PDUs), electrical distribution systems, and busbar trunking systems offers significant advantages, particularly in industrial environments and data centers.

Elektro Internationaal can handle the preparatory connection work between the distribution system and the busbar trunking during the production phase. This ensures technical alignment between the two systems, allowing the on-site connection to be executed as a "plug & play" process. This minimizes on-site installation work and reduces the likelihood of unexpected modifications during implementation.

Our expertise in both electrical distribution systems and busbar trunking allows us to collaborate on the complete power distribution setup right from the design phase. The result is a solution that not only meets current requirements but also accommodates future expansion and changing power demands.