Electropak Ltd provides a comprehensive Busbar Repair / Busbar Refurbishment Service, designed to extend the life of existing equipment and provide a cost-effective alternative to complete replacement.
What are Busbars?
Busbars are essential components in electrical power distribution systems. Typically made of copper or aluminium, they conduct electricity within vehicle engines, power trains, drive trains, switchgears, distribution boards, and other electrical apparatus.
Their role is to safely and efficiently carry large currents, often in demanding environments such as industrial plants, data centres, and transportation systems.
Because they are exposed to high electrical loads and varying environmental conditions, the longevity and performance of busbars depend on the quality of their insulation, plating, and surface condition.
Why Busbar Refurbishment Is Needed?
Over time, busbars can suffer from insulation breakdown, plating deterioration, or physical damage caused by electrical arcing. These issues not only compromise performance but can also pose safety risks. Rather than replacing entire systems, overhauling busbars offers a reliable and cost-effective solution.
Electropak Ltd specialises in restoring busbars to peak condition through a variety of proven methods:
Re-insulation: Using epoxy coating, Mylar wrapping, or heat shrink sleeving, we can restore the protective layers that keep systems safe and efficient.
Re-plating: Busbar plating can deteriorate with age or use. We provide tin, silver, and nickel plating services to ensure excellent conductivity and corrosion resistance.
Contact surface repair: In cases where arcing has damaged the contact surface, Electropak can repair and re-plate it, extending the lifespan of the busbar.
Re-tested: Every busbar is individually retested by our engineers, ensuring insulation meets the project requirements.
Importantly, our busbar refurbishment service covers not only busbars originally manufactured by Electropak, but also those supplied by third parties.
Serving a Wide Range of Industries
Electropak has decades of experience in busbar manufacturing and has supplied solutions to a diverse range of sectors.
Our customers include companies in aerospace, automotive, rail, power generation and distribution (e.g. Square D busbar systems) renewable energy, defence, maritime, and data centre industries. This breadth of expertise allows us to apply the same high standards of quality and reliability to our repair and refurbishment services as we do to our new busbar production.
Substation arrangements we can work with include Single Busbars, Double Busbars, Ring Busbar and Main and Transfer Bus.
Refurbished Square D 3000A R-H Busbar section and joint pack. Busbars and joint pack were repaired, re-plated and re-insulated, then re-assembled and tested. The trunking metalwork was repaired and re-painted
Extending Lifespan, Reducing Costs
With this service, Electropak provides businesses with the opportunity to maximise the value of their investment. By repairing and refurbishing rather than replacing, companies can reduce downtime, lower costs, and improve sustainability.
It also provides a cost effective solution to component obsolescence, where the manufacturers no longer manufacture or are able to provide repairs.
Reverse Engineering and Beyond Economic Repair (BER) Busbars
As a UKC Group company, Electropak also offers a Reverse Engineering solution to provide replacement units. This service includes the supply of a full technical data-pack: CAD Drawings, BOM, Authentication and Testing Certs
For badly damaged components, the busbar refurbishment cost many exceed the cost to remanufacture replacements. Under this scenario we can offer to re-manufacture rather than repair.
Contact Electropak
Whatever the project, to speak to an Electropak busbar engineer today about the services you require please call 01772 251444.
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