Table of Contents

Benefits of Aluminum Bus Conductor ..................................................................... 2

Alloys and Tempers ................................................................................................ 2

Special Finishes and Packaging .............................................................................. 2 Bus Pipe and Tube

Factors to Consider When Selecting a Bus Conductor ............................................... 2

Frequently Asked Questions .................................................................................... 3

Bus Packaging Options .......................................................................................... 4

Seamless Bus Pipe ................................................................................................ 5

Seamless Bus Tube .............................................................................................. 7

Rectangular Bar - Sharp Corners ............................................................................ 9

Rectangular Bar - Rounded Corners ...................................................................... 10 Integral Web (IWBC)

Integral Web Bus Conductor (IWBC)....................................................................... 13

Channel Bus Conductor ........................................................................................ 15

Square Bus Tube ................................................................................................. 17

Universal Angle Bus Conductor (UABC) ................................................................. 19

Mechanical Properties of Aluminum Bus Conductors ............................................. 21

Bending and Forming .......................................................................................... 22

Deflection Values ................................................................................................ 23

Welding Aluminum Bus to Aluminum Connectors ................................................... 25 Square Bus Tube

General Welding Specifications - Tubular Aluminum Bus Conductor ......................... 26

Channel Bus Angle (UABC) Bus Bus Bar

© 2003, AFL Telecommunications, all rights reserved. Revision 0, 11.28.05

Specifications are subject to change without notice.

1
Benefits of Aluminum Bus Conductor

• Only 1/3 the weight of copper

• Highly corrosion resistant
• Dissipates heat rapidly and evenly
• Very strong yet lightweight
• Easy to fabricate
• Conducts equivalent loads of electric power with one half as
much material weight as copper

Today, aluminum is one of the most widely specified conductive Factors to Consider When Selecting a Bus Conductor
materials used in the manufacture and construction of electrical A variety of factors must be considered in bus design. In all
power distribution components and equipment. applications, considerations include d-c or a-c current, ampacity
Typical applications presently using aluminum conductors include required, frequency, operating voltage, allowable voltage drop,
bus duct, bus bar, panel boards, switchgear, isolated phase bus maximum possible short circuit currents, available space, and the
and a host of other similarly purposed products installed virtually taps and connections required. If large currents are involved, factors
everywhere – from electric utility switchyards to substations affecting the economic current density must also be tabulated.
construction all over the world. And for outdoor substations, weather conditions such as possible
maximum icing conditions, wind speeds and similar situations
Alloys and Tempers are important. Factors that may affect the design of industrial bus
The most commonly used alloys are 6063, 6061, and 6101. Alloy include ampacity for allowable temperature rise, voltage drop and
6063 has been widely used for outdoor high voltage substation bus power loss economics.
because of its excellent mechanical and electrical properties. Where
high strength and lower conductivity is called for, alloy 6061 bus is Conductivity
used. Where high conductivity is required, with a minimum sacrifice Pure aluminum has an electrical conductivity of 65 percent of the
in mechanical properties, alloy 6101 is used. Alcoa Conductor International Annealed Copper Standard. This is decreased a certain
Accessories (ACA) aluminum bus conductors are manufactured to amount for any aluminum alloy, depending on the alloy’s composition
meet appropriate ASTM specifications. These include B-241-00 and temper. Internal heating of the conductor causes a loss of
- Aluminum Alloy Seamless Pipe and Tube for Alloys 6063 and physical strength, which limits the conductor’s current carrying
6061; and B-317-00 - Aluminum Alloy Extruded Bar, Rod, Pipe and capacity. Therefore, not only the temperature at which the alloy
Structural Shapes for Electrical Purposes for Alloy 6101. begins to anneal, but the time it takes to reach that temperature,
must be taken into consideration.
The tempering process is an application that hardens or strengthens
the metal by applying heat and/or cooling the metal. The basic Ampacity
temper consists of a letter followed by one or more numbers. The For a given value of continuously flowing current, the temperature of
most common tempers are T6, T61, and T63. T6 is solution heat a bus rises until the heat coming from the electrical losses in the bus
treated, and artifically aged to maximum mechanical property levels. is equal to the heat given off by radiation and convection.
T61 is an overaged temper with higher conductivity, but lower Bus conductor ampacities are usually based on a continuous
mechanical properties than T6. T63 is an “in-between” temper with operating temperature of 30°C above an ambient temperature of
higher conductivity than T6, but less than T61. 40°C.
The most common alloy and temper combinations are 6063-T6, Lengths
6061-T6, 6101-T6, 6101-T61, and 6101-T63. For other alloys or Bus Conductor is sold in various lengths ranging from 10 feet to 40
tempers, please contact your ACA Sales Representative. feet. Longer lengths are available in various sizes. Contact your ACA
Special Finishes and Packaging Sales Representative for more information.
ACA aluminum bus conductor is manufactured with an EHV (Extra-
High Voltage) finish and EHV packaged. EHV packaging consists of
inter-leafed paper and cardboard boxed.

© 2003, AFL Telecommunications, all rights reserved. Revision 0, 11.28.05

Specifications are subject to change without notice.

2
Frequently Asked Questions

Do I use seamless pipe or structural pipe for substation construction?

For substation construction, seamless pipe should be used. Extruded structural pipe is produced with a bridge-type die. In the bridge die
method of extrusion, the solid ingot is broken up and then rejoined in the weld chamber of the die. Thus, the pipe contains two or more “die
welds” along its length. This pipe is intended for use in structural applications such as highway and bridge rails, chain link fence posts, sign
structures, lighting brackets, etc. Structural pipe is not intended for applications involving fluid pressure or repeated flexure as there is a
possibility of splitting along the die welds. Tubular bus in substations is frequently subjected to aeolian vibration which produces repeated
flexure. Seamless pipe is extruded from hollow extrusion ingot by the die and mandrel method. The cross section is continuous; there are no
die welds to separate under repeated flexure. For more information about structural pipe look at ASTM standard B-249-00 and for seamless
pipe look at ASTM standard B-241-00.

What is the difference between bus pipe and bus tube?

Bus Pipe is manufactured to a “nominal” (not actual) diameter. The wall thickness is described by a “schedule.” i.e. 4” Sch40. Bus Tube
is a round hollow material manufactured to a specific outside diameter (O.D.) and wall thickness. It is produced to meet the end users
requirements.

Does alloy and temper matter?

Yes, the alloy and temper specify the conductivity and mechanical properties.

What is the maximum length of bus conductor I can buy?

Most bus conductor is sold in lengths of 10 to 40 feet. Longer lengths are available in various sizes. Contact the ACA Commercial Team for
any lengths over 40 feet.

Can I order custom sizes or custom extrusions?

Yes, contact the ACA Commercial Team for custom sizes of bus conductor and custom extrusions.

© 2003, AFL Telecommunications, all rights reserved. Revision 0, 11.28.05

Specifications are subject to change without notice.

3
Bus Packaging Options

Bare - Batten - Bundled (BBB)

EHV Pack - Note interweave paper to protect

© 2003, AFL Telecommunications, all rights reserved. Revision 0, 11.28.05

Specifications are subject to change without notice.

4
Seamless Bus Pipe
Seamless bus pipe is an extruded tubular product used to convey electricity. It is
manufactured to a “nominal,” not actual, inside diameter. The wall thickness is described by
a “schedule.” The schedules are determined by the American Standards Association.
Seamless bus pipe is generally made of 6063-T6 alloy in ANSI Schedule 40 pipe because of
its excellent mechanical and electrical properties. 6061-T6 alloy tubular bus is used where
high strength and lower conductivity are required.
Specification: B-241 (Seamless Pipe)
Note: For seamless bus tubing over 6 inches, see page 7.

Schedule 40 Schedule 80
Outside Outside
Wall Wall
Nominal Size Diameter of Area Weight Nominal Size Diameter of Area Weight
Thickness Thickness
Tube Tube
in in in in in in
sq in lb/ft sq in lb/ft
SCH 40 A B SCH 80 A B
1 1.315 0.133 0.4939 0.581 1 1.315 0.179 0.6388 0.751
1 1/4 1.660 0.140 0.6685 0.786 1 1/4 1.660 0.191 0.8815 1.037
1 1/2 1.900 0.145 0.7995 0.940 1 1/2 1.900 0.200 1.0680 1.256
2 2.375 0.154 1.0750 1.264 2 2.375 0.218 1.4770 1.737
2 1/2 2.875 0.203 1.7040 2.004 2 1/2 2.875 0.276 2.2540 2.650
3 3.500 0.216 2.2280 2.621 3 3.500 0.300 3.0160 3.547
3 1/2 4.000 0.226 2.6800 3.151 3 1/2 4.000 0.318 3.6780 4.326
4 4.500 0.237 3.1740 3.733 4 4.500 0.337 4.4070 5.183
4 1/2 5.001 0.247 3.6880 4.337 4 1/2 5.000 0.355 5.1800 6.092
5 5.563 0.258 4.3000 5.057 5 5.563 0.375 6.1120 7.188
6 6.625 0.280 5.5810 6.564 6 6.625 0.432 8.4050 9.884

Ordering Instructions:
Step 1: Choose Nominal Size Step 2: Choose Schedule Step 3: Choose Alloy Step 4: Choose Temper

Size Schedule Number Schedule Code Alloy Number Alloy Code Temper Temper Code
Nominal Size
Code
SCH 40 S40 6061 X T6 T6
1 100
SCH 80 S80 6063 Y T61 T61
1 1/4 125
6101 Z T63 T63
1 1/2 150 Step 5: Choose Packaging
2 200
Package Type Package Code
2 1/2 250
Bare - Bat - Bundle (BBB) B
3 300
EHV E
3 1/2 350
See pictures on page 3
4 400
4 1/2 450 Step 6: Build Catalog Number

5 500 Size Code + Schedule Code + Alloy Code + Temper + Package Code

6 600 Example: To order 2 1/2 inch Schedule 40 6101 T-61 Alloy Bus Pipe with BBB packaging
250 + S40 + Z + T61 + B
Completed Catalog Number is 250S40ZT61B.

© 2003, AFL Telecommunications, all rights reserved. Revision 0, 11.28.05

Specifications are subject to change without notice.

5
Physical & Electrical Properties of Aluminum
Standard Pipe-Size Conductors at Typical Conductivities

6063-T6 6061-T6
A B
Inductive Current Current
Nominal AC
Area Weight reactance 1 ft DC Ratings DC AC Ratings
Size 60 Hz Resistance 60 Hz
sq in lbs/ft spacing 60 Hz Resistance Amp at Resistance Resistance Amp at
in Outside Rac/RDC at 70oC Rac/RDC
Wall microhm/ft at 20oC 60 Hz (1) at 20oC at 70oC 60 Hz 60 Hz (1)
Diameter at 70oC 60 Hz at 70oC
Thickness microhms/ft (2) (3) (4) microhms/ft microhms/ft (2) (3) (4)
of Tube microhms/ft
in Outdoor Outdoor
in
Schedule 40 Pipe
1 1.315 0.133 0.494 0.581 68.24 31.120 1.00039 36.580 681 38.360 1.00032 43.820 622
1 1/4 1.660 0.140 0.669 0.786 62.68 22.990 1.00050 27.030 859 28.340 1.00039 32.370 705
1 1/2 1.900 0.145 0.800 0.940 59.45 19.220 1.00064 22.600 984 23.690 1.00046 27.070 900
2 2.375 0.154 1.075 1.264 54.15 14.300 1.00082 16.820 1234 17.630 1.00055 20.140 1128
2 1/2 2.875 0.203 1.704 2.004 49.85 9.019 1.00220 10.620 1663 11.170 1.00150 12.710 1520
3 3.500 0.216 2.228 2.621 45.19 6.897 1.00300 8.126 2040 8.500 1.00180 9.725 1865
3 1/2 4.000 0.226 2.680 3.151 42.05 5.736 1.00380 6.761 2347 7.070 1.00220 8.091 2145
4 4.500 0.237 3.174 3.733 39.28 4.842 1.00470 5.712 2664 5.968 1.00270 6.834 2436
4 1/2 5.001 0.247 3.688 4.337 36.81 4.167 1.00570 4.920 2984 5.136 1.00330 5.885 2728
5 5.563 0.258 4.300 5.057 34.31 3.574 1.00680 4.224 3348 4.406 1.00400 5.051 3063
6 6.625 0.280 5.581 6.564 30.23 2.754 1.00950 3.263 4064 3.394 1.00540 3.897 3719
Schedule 80 Pipe
1 1.315 0.179 0.639 0.751 68.81 24.060 1.00100 28.300 774 29.650 1.00075 33.840 707
1 1/4 1.660 0.191 0.882 1.037 63.14 17.440 1.00140 20.520 985 21.490 1.00105 24.570 901
1 1/2 1.900 0.200 1.068 1.256 59.89 14.390 1.00200 16.940 1137 17.730 1.00150 20.280 1039
2 2.375 0.218 1.477 1.737 54.56 10.400 1.00280 12.260 1446 12.820 1.00210 14.670 1322
2 1/2 2.875 0.276 2.254 2.650 50.23 6.820 1.00720 8.071 1907 8.406 1.00390 9.647 1746
3 3.500 0.300 3.016 3.547 45.55 5.096 1.01030 6.050 2363 6.281 1.00490 7.225 2199
3 1/2 4.000 0.318 3.678 4.326 42.39 4.178 1.01380 4.972 2735 5.150 1.00750 5.935 2507
4 4.500 0.337 4.407 5.183 39.61 3.487 1.01710 4.168 3118 4.298 1.00950 4.965 2862
4 1/2 5.000 0.355 5.180 6.092 37.13 2.967 1.02100 3.559 3505 3.657 1.01160 4.236 3221
5 5.563 0.375 6.112 7.188 34.63 2.515 1.02600 3.032 3949 3.099 1.01650 3.604 3631
6 6.625 0.432 8.405 9.884 30.58 1.829 1.04570 2.247 4891 2.254 1.02120 2.656 4532

Notes:
1. Current ratings listed in the Tables are based on 30oC temperature rise over 40oC ambient horizontally mounted conductors, with spacing sufficient to eliminate proximity
effects, generally assumed not to be significant if spacing is 18 in. or over. Conduction of heat by supporting structures and taps can appreciably affect the ratings.
2. Conductors with a 2ft/sec crosswind. Nominal oxidized surface (e=0.50)
3. Current Ratings for direct current are close to those of alternating current for all except the larger sizes; and for them, the increase for dc bus is about 1.5 percent.
4. NEMA Standard SG1-3.02 (7/13/60) lists current rating for tubes of 57%-61% IACS conductivity, but without stated emissivity factors. However, even after adjustment for the
53% IACS conductivity of 6063-T6 alloy (and 43% for 6061-T6 alloy), the ratings differ somewhat from those of this table.

© 2003, AFL Telecommunications, all rights reserved. Revision 0, 11.28.05

Specifications are subject to change without notice.

6
Seamless Bus Tube

Seamless bus tube is a round, hollow material manufactured to a specific outside diameter
(O.D.) and wall thickness. It is produced to meet specific end user requirements. Tubing
is described by the actual outside diameter and wall thickness, i.e. 8” O.D. x 0.500” Wall
aluminum tubing.
Outdoor tubular bus is generally made of 6063-T6 alloy because of its excellent mechanical
and electrical properties and is readily available. 6061-T6 tubular conductor is used where
very high strength and lower conductivity is required.

Note: For seamless bus tube sizes not listed, contact the ACA Commercial Team.

Outside
Wall Thickness Area Weight Outside Diameter
Diameter of Tube Wall Thickness Area Weight
of Tube
in in
sq in lb/ft
A B in in
sq in lb/ft
8 0.250 6.09 7.16 A B
8 0.375 8.98 10.56 10 0.312 9.50 11.17
8 0.500 11.78 13.85 10 0.375 11.34 13.33
8 0.625 14.48 17.03 10 0.500 14.92 17.55
9 0.250 6.87 8.08 10 0.625 18.41 21.65
9 0.375 10.16 11.95 12 0.312 11.46 13.47
9 0.500 13.35 15.70 12 0.375 13.70 16.11
9 0.625 16.44 19.34 12 0.500 18.06 21.24
12 0.625 22.33 26.27
Ordering Instructions:
Step 1: Choose Outside Diameter Step 2: Choose Wall Thickness Step 3: Choose Alloy Step 4: Choose Temper
Outside Diameter Wall Thickness Alloy Temper Temper Code
Alloy Number
Diameter Code Thickness Code Code
T6 T6
8 8OD 1/4” 250W 6061 X
T61 T61
9 9OD 5/16” 312W 6063 Y
T63 T63
10 10OD 3/8” 375W 6101 Z
12 12OD 1/2” 500W
5/8” 625W

Step 5: Choose Packaging Step 6: Build Catalog Number

Package Type Package Code Outside Diameter + Wall Thickness + Alloy Code + Temper + Package Code

Bare - Bat - Bundle (BBB) B Example: To order 8 inch OD 1/2” wall 6101-T61 Alloy Bus Pipe with BBB packaging
EHV E 8OD + 500W + Z + T61 + B
See pictures on page 3 Completed Catalog Number is 8OD500WZT61B.

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Specifications are subject to change without notice.

7
Physical & Electrical Properties of Large Diameter Round Tube
Amperes for 6101-T61 Alloy 57% IACS Conductivity

A B Inductive Current Rating 60 Hz Amp

DC
Moment Reactance AC Resistance
Outside Wall Weight Resistance Rac/Rda at
Area Sq In of Inertia 1 ft spacing at 70oC 60 Hz
diameter thickness lb/ft at 20oC 70oC Indoor Outdoor
1 in4 60 Hz-Xa microhms/ft
in in microhms/ft
microhms/ft
0.250 6.09 7.16 45.70 25.80 2.348 1.006 2.8070 3805 4720
0.375 8.98 10.56 65.44 26.00 1.591 1.030 1.9470 4555 5645
8
0.500 11.78 13.85 83.20 26.20 1.213 1.091 1.5730 5045 6250
0.625 14.48 17.03 99.20 26.50 0.987 1.206 1.4140 5190 6435
0.250 6.87 8.08 65.80 23.20 2.079 1.006 2.4860 4255 5245
0.375 10.16 11.95 94.70 23.30 1.406 1.030 1.7220 5100 6285
9
0.500 13.35 15.70 121.00 23.40 1.070 1.092 1.3890 5650 6965
0.625 16.44 19.34 145.00 23.60 0.869 1.308 1.2480 5980 7370
0.312 9.50 11.17 111.50 20.60 1.505 1.015 1.8140 5185 6355
0.375 11.34 13.33 131.50 20.70 1.260 1.031 1.5430 5635 6910
10
0.500 14.92 17.55 168.80 20.90 0.958 1.092 1.2430 6255 7670
0.625 18.41 21.65 203.10 21.00 0.776 1.210 1.1160 6640 8140
0.312 11.46 13.47 195.80 16.30 1.247 1.015 1.5040 6155 7480
0.375 13.70 16.11 231.60 16.40 1.043 1.031 1.2780 6685 8125
12
0.500 18.06 21.24 299.20 16.60 0.791 1.093 1.0280 7415 9015
0.625 22.33 26.27 362.30 16.70 0.640 1.213 0.9219 7850 9545

Notes:
1. Current ratings listed in the Tables are based on 30oC temperature rise over 40oC ambient horizontally mounted conductors, with spacing sufficient to eliminate proximity
effects, generally assumed not to be significant if spacing is 18 in. or over. Conduction of heat by supporting structures and taps can appreciably affect the ratings.
2. Conductors with a 2ft/sec crosswind. Nominal oxidized surface (e=0.50)
3. Current Ratings for direct current are close to those of alternating current for all except the larger sizes; and for them, the increase for dc bus is about 1.5 percent.

© 2003, AFL Telecommunications, all rights reserved. Revision 0, 11.28.05

Specifications are subject to change without notice.

8
Rectangular Bar - Sharp Corners (Standard)

Rectangular shapes are the all-purpose rigid conductor for switchgear, control apparatus and
A busways. The use of multiple bar bus can provide a large surface area for heat dissipation. Joints
and taps are easily made by bolting or welding; it is also easy to make off-sets and 90-degree bends.
B
For direct current, the capacity of a rectangular bar bus conductor can be controlled by varying the
size or number of bars in parallel. The same is true of alternating current up to certain limits. Special
arrangements of laminations are used for high-amperage alternating current.

Thickness Width Estimated Thickness Width Estimated

A B Weight per A B Weight per
in in lb/ft in in lb/ft
0.375 0.055 4.500 1.334
0.500 0.074 1/4 5.000 1.484
0.500 0.074 6.000 1.784
0.625 0.090 0.250 7.000 2.084
0.750 0.110 8.000 2.384
1/8 0.875 0.127 0.625 0.277

0.125 1.000 0.149 1.25 0.527

1.000 0.145 2 0.895
1.250 0.184 2 0.864
2.000 0.299 3/8 2.5 1.120
2.500 0.371 0.375 3 1.314
4.000 0.599 4 1.764
0.375 0.084 5 2.214
0.500 0.112 6 2.664
0.625 0.140 8 3.596
3/16 0.750 0.169 0.75 0.385
0.188 0.750 0.168 1.5 0.896
0.875 0.187 2 1.196
1.000 0.222 3 1.796
1/2
2.000 0.442 4 2.396
0.500 0.149 0.5 5 2.996
0.750 0.209 6 3.596
1.000 0.284 8 4.796
1.250 0.359 10 5.996
1/4 1.500 0.434 1 0.884
3/4
0.250 2.000 0.584 4 3.455
2.500 0.734 0.75 5 4.495
3.000 0.884 1.25 1.498
3.250 0.959 8 9.535
1
4.000 1.184 10 11.996
12 14.364

© 2003, AFL Telecommunications, all rights reserved. Revision 0, 11.28.05

Specifications are subject to change without notice.

9
Rectangular Bar - Rounded Corners (Special Order)

R
Rectangular shapes are the all-purpose rigid conductor for switchgear, control apparatus and
A busways. The use of multiple bar bus can provide a large surface area for heat dissipation. Joints
and taps are easily made by bolting or welding; it is also easy to make off-sets and 90-degree bends.
B
For direct current, the capacity of a rectangular bar bus conductor can be controlled by varying the
size or number of bars in parallel. The same is true of alternating current up to certain limits. Special
arrangements of laminations are used for high-amperage alternating current.

Thickness Width Radius Estimated Thickness Width Radius Estimated

A B R Weight per A B R Weight per
in in in lb/ft in in in lb/ft
0.375 0.031 0.055 4.500 0.125 1.334
0.500 0.016 0.074 1/4 5.000 0.125 1.484
0.500 0.031 0.074 6.000 0.125 1.784
0.625 0.062 0.090 0.250 7.000 0.125 2.084
0.750 0.031 0.110 8.000 0.125 2.384
1/8 0.875 0.062 0.127 0.625 0.062 0.277

0.125 1.000 0.031 0.149 1.25 0.188 0.527

1.000 0.062 0.145 2 0.062 0.895
1.250 0.062 0.184 2 0.187 0.864
2.000 0.031 0.299 3/8 2.5 0.062 1.120
2.500 0.031 0.371 0.375 3 0.187 1.314
4.000 0.031 0.599 4 0.187 1.764
0.375 0.031 0.084 5 0.187 2.214
0.500 0.031 0.112 6 0.187 2.664
0.625 0.031 0.140 8 0.062 3.596
3/16 0.750 0.016 0.169 0.75 0.250 0.385
0.188 0.750 0.031 0.168 1.5 0.062 0.896
0.875 0.094 0.187 2 0.062 1.196
1.000 0.062 0.222 3 0.062 1.796
1/2
2.000 0.094 0.442 4 0.062 2.396
0.500 0.031 0.149 0.5 5 0.062 2.996
0.750 0.125 0.209 6 0.062 3.596
1.000 0.125 0.284 8 0.062 4.796
1.250 0.125 0.359 10 0.062 5.996
1/4 1.500 0.125 0.434 1 0.125 0.884
3/4
0.250 2.000 0.125 0.584 4 0.375 3.455
2.500 0.125 0.734 0.75 5 0.062 4.495
3.000 0.125 0.884 1.25 0.031 1.498
3.250 0.125 0.959 8 0.250 9.535
1
4.000 0.125 1.184 10 0.062 11.996
12 0.188 14.364

© 2003, AFL Telecommunications, all rights reserved. Revision 0, 11.28.05

Specifications are subject to change without notice.

10
Ordering Instructions:

Step 1: Width of Bar Step 2: Thickness of Bar Step 3: Choose Alloy Step 4: Choose Temper
Width of Width Thickness Thickness Alloy Temper Temper Code
Alloy Number
Bar Code of Bar Code Code
T6 T6
3/8 R375 1/8 125W 6061 X
T61 T61
1/2 R500 3/16 188W 6063 Y
T63 T63
5/8 R625 1/4 250W 6101 Z
3/4 R750 3/8 375W
7/8 R875 1/2 500W
Step 5: Choose Edge Finish
1 R1i 3/4 750W
Type Radius
1 1/4 R125i 1 100W
Square (blank)
1 1/2 R15i
Rounded R
2 R2i
See pictures on page 3
2 1/2 R25i
3 R3i
Step 6: Build Catalog Number
3 1/4 R325i
Width Code + Thickness Code + Alloy Code + Temper + Radius
4 R4i
4 1/2 R45i Example: To order 1 1/4””wide x 1/8” wall thickness 6101-T6 Bus Bar

5 R5i R125i + 125W + Z + T6 + R

6 R6i Completed Catalog Number is R125i125WZT6R.

7 R7i
8 R8i
10 R10i
12 R12i

© 2003, AFL Telecommunications, all rights reserved. Revision 0, 11.28.05

Specifications are subject to change without notice.

11
Current Rating of Rectangular Aluminum Bus Bar Arrangements
Amperes for 6101-T61 Alloy 57% IACS Conductivity

Sizes 1 Bar 2 Bars 3 Bars 4 Bars

(Inches)
DC 60 HZ AC DC 60 HZ AC DC 60 HZ AC DC 60 HZ AC
1/4 x 1 308 308 607 601 605 887 1203 1168
1 1/2 430 429 833 817 1235 1194 1637 1561
2 549 545 1051 1021 1552 1480 2053 1915
3 780 768 1472 1410 2162 2000 2851 2530
4 1005 980 1878 1760 2749 2462 3619 3081
5 1225 1184 2275 2092 3321 2905 4365 3625
6 1443 1381 2665 2413 3881 3338 5095 4146
7 1870 1760 3427 3034 4974 4183 6517 5152
3/8 x 2 691 678 1340 1278 1989 1831 2638 2332
3 974 941 1857 1709 2739 2384 3620 2946
4 1249 1191 2356 2099 3460 2893 4563 3574
5 1519 1429 2842 2483 4162 3387 5479 4178
6 1785 1657 3320 2847 4848 3857 6375 4765
8 2308 2098 4253 3569 6188 4774 8119 5875
10 2822 2534 5165 4289 7493 5632 9817 6941
1/2 x 3 1145 1074 2205 1991 3265 2742 4324 3297
4 1462 1369 2782 2416 4100 3264 5417 3940
5 1774 1634 3345 2828 4912 3778 6477 4580
6 2081 1892 3897 3230 5706 4284 7514 5210
8 2685 2393 4975 4014 7255 5276 9531 6246
10 3278 2880 6209 4779 8763 6256 1149 7579

Sizes 1 Bar 2 Bars 3 Bars 4 Bars

(Inches)
DC 60 HZ AC DC 60 HZ AC DC 60 HZ AC DC 60 HZ AC
1/4 x 1 300 300 585 580 775 765 905 880
1 1/2 420 415 800 785 1060 1020 1240 1180
2 535 530 1010 980 1340 1280 1560 1460 Notes:
3 750 735 1380 1310 1850 1700 2180 1940 1. Ratings based on 30oC rise over
4 955 930 1720 1600 2300 2050 2740 2330 40oC ambient in still but confined air
5 1160 1120 2000 1830 2670 2330 3160 2610 (e=0.35), corresponding to usual indoor
6 1320 1270 2220 2010 2970 2540 3440 2800 temperature. Vertical bar ampacity based
8 1620 1520 2640 2320 3410 2840 3900 3080 on work by House and Tuttle. Horizontal
3/8 x 2 670 660 1230 1170 1620 1490 1920 1700 bar ampacity from industry sources.
3 935 905 1680 1550 2250 1960 2730 2220 2. Space between bars is assumed equal bar
4 1190 1130 2080 1860 2800 2340 3360 2630 thickness.
5 1420 1340 2420 2110 3250 2650 3850 2940 3. For ac phase spacings less than 18 inches
6 1630 1520 2710 2330 3680 2940 4280 3200 an allowance for proximity effect must be
made.
8 2000 1820 3240 2700 4210 3270 4820 3490
4. Ratings are based on horizontal mounting,
1/2 x 3 1100 1050 1870 1650 2560 2080 3070 2340
in air with no attachments. For dc ratings
4 1390 1300 2290 1960 3150 2470 3800 2750
of other alloys, multiply by: For 6101-T61,
5 1650 1520 2680 2240 3630 2780 4370 3090 0.982; 6101-T63, 0.992; 6101-T64,
6 1890 1710 3050 2490 4060 3050 4800 3330 1.02; 6101-T65, 0.996. For 60Hz, the
8 2310 2050 3640 2900 4790 3490 5510 3720 use of these multipliers is conservative.

© 2003, AFL Telecommunications, all rights reserved. Revision 0, 11.28.05

Specifications are subject to change without notice.

12
Integral Web (IWBC)

This shape is used for station bus, open or enclosed and for the high-current bus of outdoor
substations for distribution voltages, as well as for 600-volt bus for industrial plants. ACA
offers the integral web bus conductor in both ventilated and non-ventilated conditions. The
use of this shape makes it unnecessary to use the spacer clamps or welded tie-bars normally
needed across the channels between insulator supports. Although convection airflow is less
than that of a face-to-face channel arrangement, transverse strength is greater. The shallow
grooves extruded on the surface facilitate location of the centers of drilled or punched holes
for attaching base plates and taps.

Size
Wall Thickness Area Weight
Height Width
A B T
sq in lb/ft
in in in
4 4 0.156 2.439 2.87
4 4 0.250 3.781 4.45
4 4 0.312 4.460 5.25
6 4 0.250 4.780 5.62
6 4 0.375 6.020 7.10
6 4 0.375 6.950 8.17
6 5 0.375 7.600 8.94
6 6 0.375 8.600 10.15
6 6 0.550 11.220 13.19
7 7 0.500 12.840 15.10
8 5 0.375 9.080 10.68
8 5 0.500 11.750 13.82
8 8 0.500 16.120 18.96
9 9 0.625 20.040 23.57
10 10 0.625 23.500 27.64

© 2003, AFL Telecommunications, all rights reserved. Revision 0, 11.28.05

Specifications are subject to change without notice.

13
Physical & Electrical Properties of Integral-Web Channel
Bus Conductors – 6101-T6 Alloy 55.0% IACS Conductivity (minimum)
Wall Inductive
Size Moment of Inertia, in4 Current AC 60 Hz Current Rating
Thickness DC Resistance Reactance
Rating Rac/ Resistance AC-60Hz
Area Weight Rdc-20oC Xa-60Hz 1
DC 70oC RDC70oC Rac-70oC
A B T sq in lb/ft microhms ft spacing
lx-x ly-y e=0.35 60HZ microhms Indoor Outdoor
in in in per ft microhms
Indoors per ft e=0.35 e= 0.50
per ft
4 4 0.156 2.439 2.87 3.876 6.213 6.88 2260 39.02 1.020 7.017 2240 2520
4 4 0.250 3.781 4.45 5.788 9.213 4.42 2810 39.76 1.035 4.579 2276 3115
4 4 0.312 4.460 5.25 6.892 10.94 3.75 3050 40.80 1.050 3.940 2980 3360
6 4 0.250 4.780 5.62 16.35 12.74 3.50 3480 34.80 1.050 3.670 3400 3780
6 4 0.375 6.020 7.10 14.50 14.00 2.78 3900 36.60 1.080 3.000 3760 4180
6 4 0.375 6.950 8.17 22.91 17.45 2.41 4200 ---- 1.090 2.630 4020 4470
6 5 0.375 7.600 8.94 25.19 29.78 2.20 4500 32.50 1.110 2.440 4320 4800
6 6 0.375 8.600 10.15 29.73 45.98 1.95 5020 27.60 1.110 2.160 4760 5270
6 6 0.550 11.22 13.19 40.05 60.86 1.49 5730 31.40 1.220 1.820 5190 5740
7 7 0.500 12.84 15.10 64.83 95.67 1.30 6530 27.60 1.210 1.570 5940 6540
8 5 0.375 9.080 10.68 52.88 37.59 1.84 5350 29.10 1.120 2.064 5060 5560
8 5 0.500 11.75 13.82 66.84 46.67 1.42 6090 30.00 1.280 1.820 5380 5910
8 8 0.500 16.12 18.96 103.5 152.3 1.04 7740 24.70 1.260 1.310 6890 7550
9 9 0.625 20.04 23.57 162.3 240.1 0.83 9060 21.60 1.370 1.140 7740 8450
10 10 0.625 23.50 27.64 255.6 362.4 0.71 10260 19.10 1.420 1.010 8610 9350

Notes:
1. Current ratings are based on 6101-T61 alloy with standard vent-holes in web. For 6101-T6 reduce the rating by 2 percent. Indoor ratings are based on 30oC rise over 40oC
ambient in still but unconfined air, normally oxidized surface (e=0.35) and similarly for outdoor ratings, except 2 ft/sec cross wind (e=0.50). Horizontal mounting is assumed
with spacing sufficient to eliminate proximity effects, generally assumed to be 18-in. or over. For temperature rise of 50oC above 40oC ambient, the indoor ratings for 30oC
may be increased about 30 percent. Indoor ratings (D-C and A-C) calculated by computer and verified by test rounded. Outdoor ratings are calculations only.
2. For vent and notch arrangements, consult your ACA Sales Representative. The interior perimeter varies according to the washer diameters that are to be accommodated, and
as to their location per NEMA spacing. The 12 in. x 12 in. size is a opposite of two symmetric extrusions bolted together.

Ordering Instructions:
Step 1: Choose Size of IWBC Step 2: Choose Wall Thickness Step 3: Choose Alloy Step 4: Choose Temper
Size of IWBC Size Code Wall Thickness Alloy Number Alloy Code Temper Temper Code
Thickness Code
4” x 4” I44 6061 X T6 T6
5/32 156W
6” x 4” I64 6063 Y T61 T61
1/4 250W
6” x 5” I65 6101 Z T63 T63
5/16 312W
6” x 6” I66
3/8 375W
7” x 7” I77 Step 5: Choose Piece Length
0.550 550W Piece Length is a whole number between 10 feet and 40 feet.
8” x 5” I85
1/2 500W
8” x 8” I88
9” x 9” I99
10” x 10” I101 Step 6: Build Catalog Number
Size Code + Thickness Code + Alloy Code + Temper + Vented

Example: To order 8” x 8” IWBC with 1/2” wall thickness 6101 T-6 Alloy
I88 + 500W + Z + T6 + V
Completed Catalog Number is I88500WZT6V.
Example: To order 4” x 4” IWBC with 1/4” wall thickness 6063 T-6 Alloy Non-vented
I44 + 250W + Y + T6 +
Completed Catalog Number is I44250WYT6

© 2003, AFL Telecommunications, all rights reserved. Revision 0, 11.28.05

Specifications are subject to change without notice.

14
Channel

This Channel, which is really a pair of channels forming a hollow, ventilated square, is a
practical choice for high-amperage direct or alternating current above 2,000 amperes
per circuit. The aluminum channels may be placed back-to-back forming a conductor for
applications such as d-c circuits, where skin effect is not a factor. For enclosed station bus
where the space occupied by the conductor is critical, channel shapes of uniform thickness
may be used. When the channels are assembled in pairs to form open tubes, they offer
several advantages: high alternating-current ratings, high structural strength, flat outside
surfaces and virtually unrestricted interior cooling.

Dimensions (in)
T Weight
A B lb/ft
Wall
Height Length of Leg
Thickness
3 1.312 0.250 1.44
4 1.750 0.250 1.99
4 1.750 0.625 4.32
5 2.187 0.625 5.70
6 2.687 0.437 5.24
7 3.187 0.375 5.45
7 3.187 0.562 7.87
7 3.187 0.625 8.63
8 3.687 0.375 6.33
8 3.687 0.500 8.26
8 3.687 0.625 10.11
9 4.125 0.625 11.48
11 5.312 0.250 6.15
11 5.312 0.312 7.62
11 5.312 0.562 13.32
12 5.812 0.250 6.74
12 5.812 0.312 8.30
12 5.812 0.625 16.17

Outside Corner Radius

Web Thickness Corner Radius

in in
0.250 3/8
0.375 1/2
0.500 5/8
0.625 3/4

© 2003, AFL Telecommunications, all rights reserved. Revision 0, 11.28.05

Specifications are subject to change without notice.

15
Physical & Electrical Properties of Aluminum Channel
Bus Conductors
Single Channel Face to Face Pair
Dimensions
in 4 Distance to Xa-60 Hz AC AC Current Ratings
Moment of Inertia in DC
Netural X inductive Rac/Rdc at Resistance 60 Hz Amp
Area Weight Resistance
Reactance 70oC at 70oC
sq in lb/ft at 20oC Indoor Outdoor
A B T W lx-x ly-y in 1-ft spacing 60 Hz 60 Hz
microhms/ft e=0.35 e=0.55
microhms/ft microhms/ft
3 1.312 0.250 3.933 1.23 1.44 1.49 0.18 0.397 46.2 5.820 1.04 7.19 2300 2760
4 1.750 0.250 4.188 1.70 1.99 3.79 0.46 0.500 39.2 4.210 1.04 5.21 2910 3500
4 1.750 0.625 4.375 3.67 4.32 6.72 0.74 0.627 40.2 1.946 1.32 3.05 3660 4400
5 2.187 0.625 5.000 4.84 5.70 13.5 1.60 0.750 33.8 1.475 1.36 2.38 4760 5700
6 2.687 0.437 6.000 4.46 5.24 21.3 2.83 0.794 29.7 1.602 1.13 2.15 5800 6950
7 3.187 0.375 7.000 4.63 5.45 33.7 4.33 0.893 24.8 1.542 1.16 2.13 6140 7350
7 3.187 0.562 7.000 6.69 7.87 44.4 6.15 0.935 25.2 1.068 1.35 1.71 6790 8150
7 3.187 0.625 7.000 7.34 8.64 47.7 6.72 0.989 25.4 0.973 1.44 1.67 6820 8450
8 3.687 0.375 8.000 5.38 6.33 49.9 6.91 1.020 22.0 1.327 1.21 1.41 6240 7500
8 3.687 0.500 8.000 7.03 8.26 63.4 8.64 1.070 22.1 1.017 1.29 1.56 6560 7900
8 3.687 0.625 8.000 8.59 10.11 74.9 11.1 1.100 22.4 0.832 1.37 1.35 7900 9400
9 4.125 0.625 9.000 9.77 11.48 109.2 14.9 1.210 19.1 0.732 1.47 1.28 8610 10500
11 5.312 0.250 11.00 5.23 6.15 91.8 14.4 1.400 14.3 1.367 1.11 1.80 8100 9750
11 5.312 0.312 11.00 6.48 7.62 119.8 17.7 1.420 14.4 1.103 1.18 1.55 8940 10800
11 5.312 0.562 11.00 11.35 13.32 198.2 29.8 1.510 14.7 0.631 1.44 1.08 10400 12400
12 5.812 0.250 12.00 5.73 6.74 128.5 19.0 1.530 12.1 1.248 1.15 1.70 8980 10800
12 5.812 0.312 12.00 7.10 8.30 186.0 27.5 1.570 12.4 1.013 1.35 1.62 10050 12100
12 5.812 0.625 12.00 13.75 16.17 288.5 45.3 1.670 12.7 0.520 1.53 0.945 11550 13700

Notes:
1. Physical properties are for single channels; electrical properties are for two channels in face-to-face arrangement. 6101-T61 alloy, 57.0% IACS Conductivity (minimum)
2. Ratings are based on 30oC rise over 40oC ambient temperature in still but unconfined air for usual indoor conditions (e=0.35), and for 2 ft/sec cross wind for usual
outdoor conditions (e=0.50).
3. For temperature rise of 50oC above 40oC ambient, an increase of about 30 percent of current rating indoors is generally accordance with tests.

Ordering Instructions:
Step 1: Choose Height of Channel Step 2: Choose Wall Thickness Step 3: Choose Alloy Step 4: Choose Temper

Height of Height Wall Thickness Alloy Temper Temper Code

Alloy Number
Channel Code Thickness Code Code
T6 T6
3” C3 1/4 250W 6061 X
T61 T61
4” C4 5/16 312W 6063 Y
T63 T63
5” C5 3/8 375W 6101 Z
6” C6 7/16 437W
7” C7 1/2 500W
8” C8 9/16 562W Step 5: Build Catalog Number
9” C9 5/8 625W Height Code + Thickness Code + Alloy Code + Temper
11” C11 Example: To order 4 inch 1/4” wall 6101-T6 Alloy 30 ft lengths Channel Bus
12” C12 C4 + 250W + Z + T6
Completed Catalog Number is C4250WZT6.

© 2003, AFL Telecommunications, all rights reserved. Revision 0, 11.28.05

Specifications are subject to change without notice.

16
Bus Square Tube

This type of bus has low skin-effect ratio much like that of round tubes, with the additional
advantage of requiring simpler adapter plates for mounting on pedestal insulators. It is often
used for generator phase and station bus in protected enclosures. The most commonly
used alloys are 6101-T61 and 6063-T6, with staggered ventilation holes on top and bottom
surfaces.
The ampacity values for standard sizes are shown for dc and ac current, using 30°C rise over
40°C ambient in still air.

Dimensions Area
Weight lb/ft
A B C sq in

3 3/8 1/4 2.643 3.108

3 1/2 3/8 3.736 4.394
3 3/4 1/2 4.571 5.375
4 1/2 1/4 3.589 4.221
4 1/2 3/8 5.236 6.158
4 3/4 1/2 6.571 7.727
5 3/4 1/4 4.482 5.271
5 3/4 3/8 6.575 7.733
5 3/4 1/2 8.571 10.08
6 3/4 1/4 5.482 6.447
6 3/4 3/8 8.075 9.497
6 3/4 1/2 10.57 12.43

Ordering Instructions:
Step 1: Choose Size Step 2 :Choose Wall Thickness Step 3: Choose Alloy Step 4: Choose Temper
Size Wall Thickness Alloy Temper Temper Code
Size of Tube Alloy Number
Code Thickness Code Code
T6 T6
3” SQ3 1/4 250W 6061 X
T61 T61
4” SQ4 3/8 375W 6063 Y
T63 T63
5” SQ5 1/2 500W 6101 Z
6” SQ6

Step 5: Build Catalog Number

Size Code + Thickness Code + Alloy Code + Temper

Example: To order 4 inch 1/2” wall 6101-T6 Alloy Square Tube Bus
SQ4 + 500W + Z + T6
Completed Catalog Number is SQ4500WZT6.

© 2003, AFL Telecommunications, all rights reserved. Revision 0, 11.28.05

Specifications are subject to change without notice.

17
Physical & Electrical Properties of Square Aluminum
Tubular Conductors – 57% IACS Conductivity (minimum)
Outside Xa 60 Hz For 6101-T61
Square Web Moment of Inductive
Corner Area Weight DC AC AC Current Rating
size Thickness Inertia Reactance Rac/Rdc at
Radius Sq in lb/ft resistance at Resistance at 60 Hz Amp
l in4 1-ft Spacing 70oC
20oC 70oC 60Hz
A (in) B (in) C (in) microhms/ft 60 Hz e=0.35 e=0.90
microhms/ft microhms/ft
3 3/8 1/4 2.643 3.108 3.272 45.5 5.408 1.04 6.683 1880 2300
3 1/2 3/8 3.736 4.394 4.215 46.1 3.825 1.09 4.954 2170 2640
3 3/4 1/2 4.571 5.375 4.598 46.9 3.126 1.18 4.384 2250 2760
4 1/2 1/4 3.589 4.221 8.215 38.7 3.982 1.05 4.968 2450 3020
4 1/2 3/8 5.236 6.158 11.30 39.0 2.729 1.11 3.600 2880 3550
4 3/4 1/2 6.571 7.727 13.06 39.6 2.175 1.21 3.127 3040 3760
5 3/4 1/4 4.482 5.271 16.26 33.5 3.189 1.06 4.106 2980 3700
5 3/4 3/8 6.575 7.733 22.76 33.8 2.173 1.13 2.918 3490 4340
5 3/4 1/2 8.571 10.08 28.32 34.1 1.667 1.24 2.457 3810 4730
6 3/4 1/4 5.482 6.447 29.36 29.1 2.607 1.08 3.346 3540 4420
6 3/4 3/8 8.075 9.497 41.59 29.4 1.770 1.15 2.418 4170 5200
6 3/4 1/2 10.57 12.43 52.35 29.6 1.352 1.28 2.056 4570 5640

Notes:
1. Current ratings are based on 30oC rise over 40oC ambient, conductors horizontally mounted and spaced sufficiently to eliminate proximity effects. For temperature rise of 50oC
above 40oC ambient, increase ratings by about 30 percent. The e=0.35 rating applies to tubes in still but confined air (usual indoor condition) with normal oxidized surface.
The e+0.90 rating applies similarly but with flat nonmetallic paint.
2. Tabulated values apply to unventilated tubes. Ventilated tubes have about 8 percent less weight. Add 15 percent to obtain current ratings of ventilated tubes having staggered
ventilating holes spaced 4-in. apart longitudinally with hole diameters as follows: For 3-in. tube, 1 1/4 in.; for 4-in.tube, 1 1/2 in.; for 5-in. tube. 1 5/8 in.;
for 6-in. tube, 1 3/4 in.

© 2003, AFL Telecommunications, all rights reserved. Revision 0, 11.28.05

Specifications are subject to change without notice.

18
Universal Angle Bus Conductor (UABC)

The universal angle bus conductor is used for moderate-size outdoor substations at distribution
voltages. Centerline grooves make it easy to locate bolt holes. The bus can be mounted directly
on insulator caps, since both legs are of uniform thickness. In contrast to the large number of
fittings sometimes required for bus installation, angle can be easily installed using bolts. Terminal
connectors are used to make taps or flexible connections. Angle shapes are usually made of
6101-T6 alloy.

Standard - Non-Vented

Size Weight
Notching Dimensions Area
W T lb/ft
sq in
in in A B C D lb/ft
3 1/4 1/4 1.500 1.750 --- 2.375 1.57 1.83
4 1/4 1.875 1.750 2.00 2.813 1.93 2.27
4 3/8 1.875 1.750 2.00 2.813 2.85 3.36
4 1/2 3/8 2.187 1.750 2.00 3.006 3.23 3.80
5 3/8 2.313 1.750 2.00 3.256 3.60 4.24

Ordering Instructions:
Step 1: Choose Size Step 2: Choose Wall Thickness Step 3: Choose Alloy Step 4: Choose Temper

Size Wall Thickness Alloy Temper Temper Code

Size of UABC Alloy Number
Code Thickness Code Code
T6 T6
3 1/4” A325 1/4 250W 6061 X
T61 T61
4” A400 3/8 375W 6063 Y
T63 T63
4 1/2” A450 6101 Z
5” A500

Step 5: Build Catalog Number

Size Code + Thickness Code + Alloy Code + Temper

Example: To order 5” 3/8” Wall Thickness 6106-T6 Alloy UABC

A500 + 375W + Z + T6
Completed Catalog Number is A500375WZT6.

© 2003-2006, AFL Telecommunications, all rights reserved. Revision 1, 10.12.06

Specifications are subject to change without notice.

19
Physical & Electrical Properties of Uniform-Thickness
Angle Bus Conductors – 6101-T6 alloy 55.0% IACS Conductivity (minimum) (4)
Moment of Inertia Minimum Distance to Xa - 60 Hz AC Current Rating 60 Hz
Size (3) DC AC
in4 Neutral Axis Inductive Rac/Rdc at Amp (1)
Area Weight Resistance at Resistance at
Reactance 1-ft 70oC
W T sq in lb/ft 20oC 70oC 60Hz Indoor Outdoor
lx or y lz x or y z Spacing 60 Hz
in in microhms/ft microhms/ft e=0.35 e=0.50
microhms/ft
3 1/4 1/4 1.57 1.83 1.60 0.65 0.91 1.30 51.41 11.20 1.024 11.49 1300 1902
4 1/4 1.93 2.27 3.02 1.18 1.09 1.51 46.60 9.07 1.045 9.46 1550 2236
4 3/8 2.85 3.36 4.35 1.75 1.14 1.60 46.62 6.14 1.115 6.85 1850 2654
4 1/2 3/8 3.23 3.80 6.31 2.61 1.26 1.77 43.93 5.42 1.145 6.20 2050 2885
5 3/8 3.60 4.24 8.75 3.50 1.39 1.96 41.52 4.86 1.175 5.71 2250 3130

Notes:
1. Indoor current ratings are based on 30oC rise over 40oC ambient in still but unconfined air, normally oxidized surface (e=0.35). Outdoor ratings are based similarly, but with 2
ft/sec crosswind (e=0.50). Horizontal mounting is assumed with spacing sufficient to eliminate proximity effects, generally assumed to be 18-in. or over. Indoor ratings based
on work by House and Tuttle. Outdoor ratings from IEEE paper by Prager, Pemberton, Craig and Bleshman.
2. Back-to-back angles are to be considered as separate members; not as a composite.
3. Alignment grooves are extruded to facilitate centering of holes according to NEMA standard spacings.
4. A modification of this design has a lug at top that does not interfere with bolting, yet it strengthens the shape against tendency to roll-over to the z-z axis in long spans sub-
jected to large lateral short circuit forces. For equal weight of shape, the z-z radius of gyration is increased by 20 percent. The stress that causes roll-over is thereby increased
about 40 percent.

© 2003, AFL Telecommunications, all rights reserved. Revision 0, 11.28.05

Specifications are subject to change without notice.

20
Mechanical Properties of Aluminum Bus Conductors

The Table below shows the mechanical properties of the aluminum alloys and tempers generally used for bus conductor. From this
information, the best combination of properties can be selected for a particular application. For example, where the cost of power is important,
high electrical conductivity is a key factor. In outdoor applications, mechanical properties are a prime consideration. Other factors, such as
yield strength and tensile strength may are taken into consideration.

Mechanical Properties of Aluminum Bus Conductor & Related Alloys

Tensile Strength (ksi) Typical (a)
Alloy at 20oC (68oF)
Thickness Typical Typical Elongation
Product and
in Minimum Minimum Ultimate (b) Yield (b) (Percent - in
Temper
Ultimate (b) Yield (b) 2 in. or 4 Dia.)

6101-T6 0.125-0.500 29.0 25.0 32.0 28.0 15.0

0.125-0.749 20.0 15.0
6101-T61 0.750-1.499 18.0 11.0
Extruded rod,
1.500-2.000 15.0 8.0
bar tube, pipe
6101-T63 0.125-0.500 27.0 22.0
6101-T64 0.125-1.000 15.0 8.0
6101-T65 0.125-0.749 25.0 20.0
Pipe size 1.0
Extruded Pipe 6061-T6 38.0 35.0 45.0 40.0 10.0 min
and over
(c)
6063-T6 Pipe size, all 30.0 25.0 35.0 31.0 8.0 min

(a) Elongation values apply to specimens of sizes related to product uses.

(b) Values apply to ANSI net stress area of regular or semi-finished bolts.
(c) Values apply to ASTM B241 seamless pipe.

© 2003, AFL Telecommunications, all rights reserved. Revision 0, 11.28.05

Specifications are subject to change without notice.

21
Bending & Forming Bus Conductor

Aluminum bus conductors can be formed by the same Flatwise Bends for Rectangular Bus
procedures and practices that are used for other metals. Type of Thickness Radius
Alloy and Temper
The most important factors governing to consider when Bar in min.1
bending bus conductor are: 0.125-0.375 2 x thickness
6101-T6
1. The ductility of the conductor 0.376-0.500 2 1/2 x thickness

2. The size and shape of the conductor 0.125-0.500 1 x thickness

3. The method of bending 0.501-0.749 2 x thickness

6101-T61
4. The bending equipment used 0.750-1.000 3 x thickness
1.001-1.625 4 x thickness
A metal must be ductile enough to allow stretching and
Extruded 0.125-0.375 1 x thickness
compression to take place. Elongation alone is not a
6101-T63 0.376-0.500 1 1/2 x thickness
complete criterion for ductility. The ration of yield strength
0.501-1.000 2 1/2 x thickness
to tensile strength must also be taken into account. A
0.125-0.750 1 x thickness
combination of a high elongation value and a low ratio 6101-T64
of yield strength to tensile strength provides the most 0.751-1.00 2 1/2 x thickness

satisfactory ductility. 0.125-0.500 1 x thickness

6101-T65
0.501-0.749 2 x thickness
The size and the shape of the bus conductor is another
factor that must be taken into consideration. For example, 1. Applicable to widths up through 6 inches in the T6, T61, T63 and T65 tempers and to
widths up through 12 inches for all other listed tempers. Blend radii for greater widths are
in case of a tube, the sharpness of a bend depends not subject to inquiry.
only on the diameter of the tube, but also on the ratio of
wall thickness to the diameter. When making edgewise
bends of rectangular bar, tests have shown that the radius
(in terms of width of the bar) around which a bar can be
bent satisfactorily depends not only on the ductility of the
car but also on its ratio of width to thickness.
Extruded, rolled, and sawed-plated bus bars can be bent
flatwise at room temperature through an angle of 90
degrees to minimum inside radii.
Tubular conductors made alloys 6063-T6 and 6061-T6
are often bent to form turns and offsets In these cases,
specifications should require seamless pipe made by
holow ingot process (ASTM B241). Ideally, the ratio of
tensile yield to tensile ultimate should not exceed 0.85. It
is vital to specify that severe forming will be encountered
and optimum heat treatments are required.
For substations, inside radii of five to seven times the
nominal pipe size for ASA schedules 40 and 80 pipe of
6063-T6 and 6061-T6 alloys should produce satisfactory
results with conventional bending tools.

© 2003, AFL Telecommunications, all rights reserved. Revision 0, 11.28.05

Specifications are subject to change without notice.

22
Deflection Values of Schedule 40 Aluminum Pipe

Nominal Pipe
Conditions 10 15 20 25 30 35 40 45 50
Size - in
1 0.15 0.76 2.39
1 1/4 0.09 0.46 1.45 3.55
1 1/2 0.07 0.35 1.09 2.67
2 0.04 0.21 0.68 1.65 3.46
2 1/2 0.03 0.15 0.47 1.15 2.38 4.22
Bare
3 0.02 0.10 0.31 0.76 1.58 2.93 5.00
3 1/2 0.02 0.08 0.24 0.58 1.20 2.21 3.78 6.07
4 0.01 0.06 0.19 0.45 0.94 1.74 2.96 4.76 7.26
5 0.01 0.04 0.12 0.29 0.61 1.12 1.91 3.08 4.69
6 0.01 0.03 0.08 0.20 0.42 0.79 1.34 2.15 3.28
1 0.43 2.20 6.96
1 1/4 0.24 1.23 3.89 9.62
1 1/2 0.17 0.88 2.80 6.83
2 0.10 0.52 1.63 4.00 8.36
2 1/2 0.06 0.30 0.96 2.30 4.89 9.05
1/2 in. ice
3 0.04 0.19 0.60 1.47 3.06 5.72 9.75
3 1/2 0.03 0.14 0.44 1.08 2.24 4.16 7.16 11.46
4 0.02 0.11 0.34 0.83 1.71 3.17 5.42 8.73 13.31
5 0.01 0.07 0.21 0.51 1.05 1.95 3.34 5.37 8.19
6 0.01 0.04 0.14 0.34 0.71 1.32 2.25 3.60 5.49
1 0.56 2.85 9.02
1 1/4 0.30 1.53 4.84 11.81
1 1/2 0.21 1.08 3.40 8.30
1/2 in. ice
2 0.12 0.61 1.93 4.70 9.75
4 lb Wind 2 1/2 0.07 0.34 1.09 2.65 5.49 10.17
3 0.04 0.21 0.67 1.64 3.40 6.30 10.76
Plus
3 1/2 0.03 0.15 0.49 1.19 2.47 4.58 7.81 12.51
Constant
4 0.02 0.12 0.37 0.90 1.86 3.45 5.89 9.43 14.38
5 0.01 0.07 0.22 0.55 1.13 2.10 3.57 5.72 8.72
6 0.01 0.05 0.15 0.36 0.75 1.39 2.37 3.80 5.79
1 0.88 4.44 14.03
1 1/4 0.47 2.37 7.47 18.49
1 1/2 0.34 1.69 5.35 13.07
2 0.18 0.92 2.91 7.09 14.95
2 1/2 0.10 0.50 1.59 3.87 8.03 15.06
1 in. ice
3 0.06 0.31 0.97 2.37 4.91 9.20 15.69
3 1/2 0.04 0.22 0.70 1.70 3.53 6.53 11.14 18.06
4 0.03 0.16 0.52 1.27 2.63 4.88 8.32 13.49 20.56
5 0.02 0.10 0.31 0.76 1.57 2.91 4.97 8.05 11.74
6 0.01 0.06 0.21 0.50 1.04 1.92 3.28 5.26 8.02

Notes:
1. These are maximum deflection values in inches for a simple beam with uniformly distributed load. For beams fixed at both ends, the deflection will be one-fifth of the values given.
2. Deflection d1 for any other span L1 may be obtained from the relation: d1=d L14/L4

© 2003, AFL Telecommunications, all rights reserved. Revision 0, 11.28.05

Specifications are subject to change without notice.

23
Deflection Values of Schedule 80 Aluminum Pipe

Nominal Pipe
Conditions 10 15 20 25 30 35 40 45 50
Size - In
1 0.16 0.81 2.56
1 1/4 0.10 0.49 1.54 3.77
1 1/2 0.07 0.36 1.15 2.82
2 0.04 0.23 0.72 1.76 3.65 6.76
2 1/2 0.03 0.16 0.49 1.21 2.50 4.64 7.92
Bare
3 0.02 0.10 0.33 0.80 1.66 3.08 5.25 8.40
3 1/2 0.01 0.08 0.25 0.60 1.25 2.32 3.97 6.36 9.69
4 0.01 0.06 0.19 0.47 0.98 1.82 3.11 4.98 7.58
5 0.01 0.04 0.12 0.31 0.63 1.17 2.01 3.21 4.89
6 0.01 0.03 0.09 0.21 0.44 0.82 1.40 2.25 3.43
1 0.40 2.01 6.34
1 1/4 0.22 1.11 3.51 8.65
1 1/2 0.16 0.79 2.51 6.12
2 0.09 0.46 1.45 3.54 7.40 13.72
2 1/2 0.05 0.28 0.88 2.15 4.46 8.33 14.20
1/2 in. ice
3 0.03 0.17 0.55 1.35 2.80 5.23 8.93 14.30
3 1/2 0.02 0.13 0.40 0.99 2.05 3.80 6.50 10.47 15.96
4 0.02 0.10 0.31 0.75 1.56 2.89 4.95 7.96 12.14
5 0.01 0.06 0.20 0.49 1.01 1.88 3.20 5.13 7.81
6 0.01 0.04 0.13 0.32 0.67 1.24 2.11 3.38 5.15
1 0.50 2.53 7.99
1 1/4 0.27 1.34 4.24 10.36
1 1/2 0.94 2.97 7.24
1/2 in. ice
2 0.10 0.53 1.66 4.06 8.42 15.60
4 lb Wind 2 1/2 0.06 0.31 0.98 2.39 4.95 9.17 15.65
3 0.04 0.19 0.60 1.47 3.06 5.66
Plus
3 1/2 0.03 0.14 0.44 1.07 2.21 4.10 7.00 11.21 17.08
Constant
4 0.02 0.10 0.33 0.81 1.67 3.09 5.28 8.45 12.88
5 0.01 0.06 0.20 0.49 1.01 1.88 3.20 5.13 7.81
6 0.01 0.04 0.13 0.32 0.67 1.24 2.11 3.38 5.15
1 0.76 3.86 12.21
1 1/4 0.40 2.02 6.39 15.80
1 1/2 0.28 1.40 4.42 10.79
2 0.15 0.77 2.43 5.94 12.46 23.09
2 1/2 0.09 0.44 1.38 3.37 6.99 13.10 22.34
1 in. ice
3 0.05 0.26 0.84 2.04 4.24 7.93 13.53 21.67
3 1/2 0.04 0.19 0.60 1.46 3.03 5.61 9.60 15.52 23.65
4 0.03 0.14 0.45 1.09 2.26 4.19 7.16 11.54 17.59
5 0.02 0.08 0.26 0.65 1.34 2.48 4.25 6.85 10.44
6 0.01 0.05 0.17 0.42 0.87 1.61 2.75 4.41 6.72

Notes:
1. These are maximum deflection values in inches for a simple beam with uniformly distributed load. For beams fixed at both ends, the deflection will be one-fifth of the values given.
2. Deflection d1 for any other span L1 may be obtained from the relation: d1=d L14/L4

© 2003, AFL Telecommunications, all rights reserved. Revision 0, 11.28.05

Specifications are subject to change without notice.

24
Welding Aluminum Bus to Aluminum Connectors

Welding of aluminum in electrical construction offers a

superior and economical means of joining conductors.
Electric arc welding using an inert gas shield produces
mechanically and electrically sound joints requiring no flux
or special surface preparation other than the cleaning of
the surface to be welded.
A welded connection that is mechanically satisfactory is
also electrically satisfactory. With welded connections,
there is an essentially homogeneous union that gives a
permanent stable connection. It is not necessary to try
to produce a connection with the same resistance as bus
itself in order to have a stable permanent joint.
There are bus connectors where it is important to insure
a resistance ratio of unity with the conductor itself.
Small differences in resistance can affect the current
distribution in some bus systems. Some bus systems
require equalization bars. Welded connections are an
ideal solution to both problems. Such connections can be
made by following procedures outlined in The American
Welding Society Handbook “Welding Aluminum.”

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Specifications are subject to change without notice.

25
General Welding Specifications for
Tubular Aluminum Bus Conductor
The following items cover key points that should be included 4. The working area should be substantially draft free and
in specifications for welding aluminum bus conductors. It is should be protected from atmospheric contamination.
recommended that the references be reviewed in the preparation of 5. All connections should be checked before, during and after
proprietary welding specifications. the weld is made. Before the weld is begun, visually inspect
1. The welding process and all welding operators should be the connection to determine proper edge preparation
qualified in accordance with the Aluminum Association, and alignment. During the weld, maintain a smooth and
“Aluminum Construction Manual” Section 7.2.4 continuous flow of metal into the joint and maintain a
“Qualification of Welding Procedure and Welding.” constant current setting on the welding station. When
2. All Joints to be welded should be free of moisture and several passes are to be made, check the previous pass
hydrocarbon. Moisture can be removed thermally, but the before laying down the next one to enable detection of poor
temperature applied should not exceed 250oF (121oC). fusion or cracks. Defective areas should be removed with
Degreasing should be done with a non-toxic solvent so as a dry chisel prior to application of subsequent weld passes.
to leave a minimum of residual on the parts. Sufficient After the weld has been complete, it should be visually
time must be allowed for evaporation of the solvent prior inspected again for quality and to insure the weld bead is of
to welding. Wire brushing with a stainless steel wire brush the correct size. The cross sectional area of the weld should
should be employed after solvent cleaning to remove thick not be less than that of the smallest member being joined.
heat-treat oxide films, water stains, etc., to permit optimum 6. Members being joined should be tack welded in place to
fusion and soundness of the weld. prevent misalignment during the welding process.
3. All welds should be made by the gas metal-arc (MIG) or the
gas tungsten-arc (TIG) welding process. Reversed polarity
direct current should be used for MIG welding, whereas
alternating current should be used for TIG welding. The
shielding gas should be welding grade Argon, Helium, or a
mixture of the two. Filler alloy 4043 should be used.

© 2003, AFL Telecommunications, all rights reserved. Revision 0, 11.28.05

Specifications are subject to change without notice.

26