Air Insulated Aluminium Bus Duct Systems (2000A | 3200A | 4000A)

Overview

A Bus Duct is a prefabricated, factory-tested power distribution system consisting of aluminium or copper conductors housed within a metal enclosure, used to transmit large amounts of electrical power over short to medium distances within a facility — commonly between a transformer and the main LT panel, or between the main panel and sub-distribution boards on different floors. As a manufacturer of Air Insulated Aluminium (AL) Bus Ducts in 2000A, 3200A, and 4000A ratings, we provide a safer, more space-efficient, and more reliable alternative to conventional cable-based power transmission for high current applications.

Advantages Over Cable Systems

Compared to running multiple parallel cables to carry heavy currents, Air Insulated Bus Duct systems offer significant advantages:

• Lower Voltage Drop & reduced power losses.

• Space-Efficient: Requires significantly less installation space.

• Easy Expansion: Easier future load addition through tap-off boxes.

• Better Heat Dissipation for enhanced safety and efficiency.

• Simplified Maintenance: The entire system is modular, easily accessible, and manageable.

Construction & Build Quality

Our bus ducts are constructed with:

• High-Conductivity Busbars: High-purity aluminium busbars, insulated and spaced as per strict air-insulation clearance norms.

• Robust Enclosure: Housed in a durable galvanized or powder-coated sheet steel enclosure with IP54/IP55 protection.

• Wide Application Range: Suitable for connecting large transformers (1000 KVA to 5000 KVA and above) to main LT panels in industrial plants, data centres, commercial high-rises, and process industries where heavy current transmission with minimal losses is essential.

• Reliable Site Joining: Each bus duct section is factory assembled and tested, then joined on-site using bolted joint kits with proper torque specification and joint resistance testing to ensure long-term reliability.

Key Features

• High-Purity Aluminium Conductors: 99.5% conductivity grade, sized for continuous full load current.

• Standard Compliant Design: Air-insulated design as per IS 8623 / IEC 61439-6 with proper phase segregation and clearances.

• Flexible Routing Sections: Horizontal, vertical, and flexible (expansion) sections for adapting to building layout and thermal expansion.

• Tap-Off Box Provisions: Available at required intervals for future load connections without shutting down the main feed.

• Fire Safety Barriers: Fire barrier sections provided where the bus duct passes through floor slabs or fire compartments.

• Temperature Rise Tested: Tested as per standards to ensure joints and conductors remain within safe operating limits.

• Weatherproof Options: Outdoor sections available for bus ducts running between outdoor transformers and indoor switchgear rooms.

Proven Value in Heavy Projects

Our 4000A bus duct installations have been particularly valuable for large industrial and commercial projects where multiple heavy cables would otherwise be required, creating congestion in cable trenches and increasing installation time. The modular nature of bus duct systems also significantly reduces on-site installation time compared to cable laying, terminations, and glanding work.

Quality Assurance & Testing

Every bus duct section undergoes rigorous routine testing before dispatch:

• Insulation Resistance Test

• High Voltage Withstand Test

• Visual & Dimensional Inspection

For critical projects, we also offer temperature rise type test reports and short-circuit withstand test certification from accredited third-party laboratories.

Why Choose Us?

• Extensive Range: Manufacturing capability across the full range from 800A to 4000A+ ratings.

• Engineering Support: Full assistance for site layout planning, including bends, offsets, and expansion joints.

• Fast Delivery: Factory assembled, ready-to-install sections for quick site execution.

• Complete Documentation: Includes joint torque records and test certificates.

• Site Support: On-site installation supervision and commissioning support