The calculation, without hidden assumptions
Estimate rectangular bare busbar mass from cross-sectional area, length and material density. This is a geometry-and-density procurement tool; it deliberately does not invent an ampacity from dimensions alone.
How to use this calculator
Choose copper, aluminium or custom density.
Enter rectangular width and thickness in mm or inches, then length per bar and physical bar quantity.
Use allowance for cutting/procurement only when appropriate; no hidden phase, neutral or earth bars are added.
Optionally enter a target mass to reverse-solve whole equal-length bars, or supplier kg/m to reconcile theoretical geometry with a catalogue value.
Use manufacturer dimensions and certified/published mass for final purchasing or lifting where rounded corners, plating or tolerances matter.
Where people use it
- •Copper busbar material takeoff for panels and switchboards.
- •Aluminium busbar mass and logistics planning.
- •Compare supplier kg/m with ideal rectangular geometry.
- •Estimate total mass for parallel bars, phases, neutral and earth by entering their physical quantity.
- •Reverse a handling or material-mass target into whole equal-length bars.
Example: 100 × 10 mm copper busbar
Area is 1,000 mm². At 8,960 kg/m³ the ideal mass is 8.96 kg/m. Ten 2 m bars therefore contain 179.2 kg before any allowance.
What the result does not assume
- •Theoretical rectangular mass excludes corner radii, edge rounding, holes, slots, bends, joints, fasteners and supports.
- •Tin, nickel or other plating is not modelled separately; use supplier mass when coating weight matters.
- •Copper and aluminium grades vary slightly in density. Use a documented grade density when precision matters.
- •This calculator does not determine current carrying capacity, temperature rise, short-circuit withstand, clearances, creepage, support spacing or code compliance.
- •Final switchgear/busbar design requires applicable standards, manufacturer data and competent electrical/structural review.
Frequently asked questions
How much does a 100 × 10 mm copper busbar weigh per metre?+
Using 8,960 kg/m³, the ideal rectangular mass is 8.96 kg/m. A manufactured rounded-edge product can differ slightly.
What density does the calculator use for aluminium?+
The aluminium preset uses 2,700 kg/m³. Enter a documented custom density when the actual alloy value differs.
Does busbar weight tell me its ampacity?+
No. Ampacity depends on material conductivity, dimensions, orientation, ambient temperature, enclosure, surface condition, allowable temperature rise and other design conditions.
Are phase and neutral bars added automatically?+
No. Quantity is always the number of physical equal-length bars you want included, so the state remains explicit.
Why can supplier kg/m differ?+
Published products can have rounded corners, dimensional tolerances, different alloy density or plating. The optional supplier field reports the variance instead of hiding it.
Can I use inches and feet?+
Yes. Dimension and length units convert into the same SI geometry engine, and the result includes both kg/m and lb/ft.
Semantic next steps
Continue the calculation
These links move to a different input, formula or project stage rather than a keyword variation of this page.
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MAXScanner keeps the formula and assumptions beside the result so you can verify the number before using it in a drawing, estimate, specification, worksheet or document. Where a supplier, manufacturer, drawing or applicable standard owns a requirement, that source remains authoritative.