Busway Products
JW-FSMC Waterproof Cast Copper Busway
I. Product Overview
The polyurethane-blended inorganic mineral epoxy resin copper busbar cast busway is a new type of power distribution device with no metal enclosure. It is suitable for AC 50Hz systems with a rated voltage below 1000V and a rated operating current from 400A to 6300A, for 50-60Hz three-phase four-wire and three-phase five-wire power supply and distribution systems. The product uses a sandwich-type, tightly laminated phase conductor design: high-performance composite insulation material is cast directly around the copper busbars to form a fully enclosed, air-gap-free monolithic structure with an IP68 protection rating, enabling reliable operation in extreme environments such as long-term water immersion, high dust, and strong corrosion. The product complies with the national standard GB/T 7251.6-2015 and is an ideal power distribution choice for shipbuilding, chemical processing, metallurgy, rail transit, data centers, nuclear power, marine engineering, and other applications with high safety requirements.
II. Core Structure
The polyurethane-blended inorganic mineral epoxy resin copper busbar cast busway uses a fully enclosed, integrally cast structure made of three core parts: high-purity copper busbar conductors, high-performance composite insulation material, and an integrally cast insulating protective layer.
For the conductor, high-purity electrical copper drawn from national-standard T2 electrolytic copper is used, with copper content no less than 99.90% and resistivity below 0.01777 Ω·mm²/m. The copper busbars use a fully rounded-edge "R-bar" design with tin plating along the full surface length, effectively enhancing oxidation and corrosion resistance and reducing contact resistance. Tin-plated joints reduce contact resistance by 15%, minimizing heat generation, and cut energy loss by up to 8% compared with unplated solutions. Busbar cross-section and length are designed to specific load requirements, ensuring stable operation under full-load conditions.
For the insulation system, the product is cast as a single piece from a composite insulation material combining polyurethane-blended inorganic minerals with epoxy resin. This composite insulation material is precisely formulated from epoxy resin, quartz sand, and various inert inorganic mineral materials according to a specific recipe and process, delivering superior electrical insulation performance, mechanical performance, and heat dissipation. The composite insulation material can contain 80% to 90% inorganic material, precisely proportioned with epoxy resin, curing agent, toughening agent, silane coupling agent, and other components, and is cured as a single piece through a vacuum mixing and casting process. The insulation material is halogen-free and releases no harmful gases when exposed to fire; it is self-extinguishing, rated Class A for fire resistance, with an F120 fire rating.
For the enclosure, the product has no metal enclosure — it is cast as a single piece from high-performance composite insulation material, eliminating air gaps and preventing enclosure electrochemical corrosion. The insulation material's coefficient of linear expansion is very close to that of copper, allowing it to expand and contract in sync with the copper busbars under temperature changes, effectively preventing insulation cracking and enhancing the thermal stability of the Busway system. The insulation material has a high thermal conductivity and good heat dissipation, formulated from a range of inert inorganic minerals and specialty epoxy resin using an optimal recipe and a special vacuum mixing and casting process to ensure good heat dissipation.
The product has a compact, modular design, with standard section lengths of up to 6 meters, greatly reducing the number of connection points, lowering overall system impedance by 15%, and significantly improving power transmission efficiency. The joints use a dual-locking method combining mechanical clamping and cast sealing, ensuring a reliable, maintenance-free connection.
III. Core Performance Features
Outstanding waterproof performance. The product is cast as a single piece from high-performance composite insulation material, offering excellent air-tightness and water-tightness with an IP68 protection rating. IP68 is the highest protection class, preventing dust ingress and enabling long-term reliable operation even under continuous water immersion. The product can operate submerged in water for extended periods or be buried underground, with no altitude restrictions. Inter-section joints are cast on site; once busway installation is complete, the system protection rating reaches IP68, making it suitable for harsh environments such as high-humidity outdoor areas and cable trenches.
Excellent fire resistance. The composite insulation material is self-extinguishing, rated Class A for fire resistance with an F120 fire rating; it can withstand flames of 950-1000°C for more than 90 minutes without circuit interruption, and the insulating resin is halogen-free, releasing no harmful gases at high temperatures. It meets the requirements of the 750°C three-hour burning test and is suitable for applications with strict fire-safety requirements. The product prevents flame spread under fire conditions without requiring a dedicated busway fire-barrier unit.
Outstanding corrosion resistance. Metal-enclosed busways cannot resist acid-rain corrosion, and corrosive gases and liquid splashes generated in chemical plants can damage electrical equipment. The epoxy resin casting compound used in Cast Busway has excellent anti-corrosion performance, effectively resisting attack from various chemicals. The cured synthetic resin has excellent alkali, acid, and solvent resistance and resists most molds, enabling long-term safe operation in highly polluted or corrosive environments. The product has passed a 96-hour salt spray test with no corrosion.
Reliable explosion-proof performance. The Busway system, cast entirely in epoxy resin, provides high sealing performance that isolates live parts from flammable gases, ensuring safe operation in flammable and explosive environments. The product can withstand a 6-joule mechanical impact, ensuring safe use, and offers good explosion-proof performance. It can also withstand mechanical shocks above 6G, meeting the requirements of harsh operating conditions.
Strong electrical insulation performance. The excellent casting process creates a seamless bond between the insulation layer and the conductor, avoiding partial discharge caused by air gaps and improving insulation strength by more than 30%. The product's normal insulation resistance can reach above 1000 MΩ, effectively avoiding short-circuit risks caused by humidity or dust. The air-gap-free design eliminates the chimney effect; once installed and running, the product is maintenance-free for life.
Efficient heat dissipation and excellent temperature-rise control. The composite insulation material is formulated from a range of inert inorganic minerals and specialty epoxy resin using an optimal recipe and special vacuum mixing and casting process, giving it high thermal conductivity and good heat dissipation. The composite insulation material has a thermal conductivity of about 0.2 W/m·K, dissipating heat effectively; under full-load operation, its operating temperature is 20°C lower than standard PVC-insulated busways. The unique composite insulation material formulation ensures the thermal expansion coefficient of the insulation matches that of the conductor, effectively preventing insulation cracking.
High mechanical strength and impact resistance. The cured composite insulation material has high mechanical strength, wear resistance, and impact resistance, giving the product an impact-resistance rating as high as IK10. The fully enclosed cast structure gives the product excellent dynamic thermal stability and an extremely low fire load. The product has a compact design with a small footprint — only 17% the volume of a traditional air-insulated busway — taking up less space and making on-site layout convenient.
All-weather adaptability. The product's use is not limited by altitude; it can operate long-term in environments as cold as -40°C without the insulating resin cracking, and can be used long-term indoors or outdoors in the highest pollution level (Level 4) environment. Its temperature range covers -40°C to 120°C, suiting all types of climate conditions worldwide.
Significant energy savings. Under the same operating conditions and current density, current-carrying capacity is 10% to 20% greater than traditional busways; for the same rating, volume is 1/2 (low voltage) to 1/10 (medium voltage) smaller. Energy savings can reach 8% to 30%, and conductor material usage is reduced by 8% to 20% compared with traditional busways under the same conditions.
IV. Core Manufacturing Process Features
The polyurethane-blended inorganic mineral epoxy resin copper busbar cast busway employs a number of advanced manufacturing technologies to ensure product precision, reliability, and consistency.
Precise formulation and raw material control. The composite insulation material is precisely formulated from epoxy resin, polyurethane, and various inert inorganic mineral materials according to a specific recipe and process. In a typical casting compound ratio, inorganic material accounts for about 80-84 parts, combined epoxy resin about 21-28 parts, toughening agent about 11-14 parts, and curing agent about 13-15 parts, plus appropriate amounts of silane coupling agent, peroxide initiator, and other additives. Key raw materials such as epoxy resin and curing agent are imported from Europe for an absolute quality advantage, and conductors are sourced from qualified manufacturers with performance exceeding national standards, under strict inspection and control procedures.
Imported German vacuum casting equipment. Jiuwei Busway Technology uses original imported German vacuum casting equipment featuring precise metering and vacuum mixing systems; the entire casting, batching, and vacuum-mixing process is completed automatically by the equipment, effectively avoiding product quality issues caused by human error. The imported German vacuum casting and mixing equipment allows continuous, digitally controlled metering and uniform mixing of raw materials, stirred under vacuum conditions.
Strict production environment control. Cast busway production has strict environmental and process parameter requirements; temperature and humidity must be controlled within specific ranges. Jiuwei Busway Technology's casting workshop is equipped with an air-conditioning system that strictly controls temperature and humidity, effectively ensuring stable and consistent product quality. Temperature, pressure, and time parameters must be strictly controlled during production to ensure the insulation layer is free of bubbles and defects.
Comprehensive quality inspection system. Quality inspection includes electrical performance tests (such as withstand-voltage and insulation resistance measurement), mechanical strength tests, and environmental adaptability verification. The cast busway system can withstand a 3750V power-frequency withstand-voltage test for one minute with no breakdown or flashover. A contact resistance tester is used to control joint contact resistance, ensuring joint temperature rise meets standard requirements.
Modular design and factory prefabrication. Before leaving the factory, the product is prefabricated into straight sections, corner sections, T-sections, and end caps according to specific project layout requirements, making on-site installation convenient. Prefabricated modules reduce on-site labor by 40%, require no secondary waterproofing, and shorten commissioning time. Standard section lengths of up to 6 meters greatly reduce the number of connection points.
On-site joint casting process. Inter-section joints are cast on site — the joint location is the area most prone to faults. On-site connections use a contact resistance tester to control contact resistance and ensure controlled joint temperature rise. The insulation material is mixed on site using small vacuum equipment, fully ensuring joint performance. Joints use a dedicated Y-type waterproof connector for reliable, convenient connection.
V. Diverse Application Scenarios
Thanks to its comprehensive performance in waterproofing, fire resistance, corrosion resistance, explosion protection, high insulation, and high mechanical strength, the polyurethane-blended inorganic mineral epoxy resin copper busbar cast busway is widely used in applications with stringent requirements for the continuity and safety of power supply.
(1) Shipbuilding and Marine Engineering
Ships, offshore platforms, and port facilities operate in marine environments with high salt spray, high humidity, and strong corrosion, demanding extremely strict corrosion resistance and waterproofing from electrical equipment. The epoxy resin casting compound in Cast Busway offers excellent anti-corrosion performance, effectively resisting seawater salt-spray corrosion. Its IP68 protection rating withstands wave impact and long-term submersion for safe use. The product can withstand salt corrosion and vessel vibration shock, and is widely used in shipbuilding, docks, offshore wind farms, and coastal industrial zones.
(2) Petrochemical and Metallurgical Industries
Chemical plants, oil refineries, steel mills, and similar facilities contain large amounts of corrosive gases and liquids and flammable/explosive environments, demanding extremely high safety and reliability from power distribution equipment. Cast Busway's composite insulation material offers excellent alkali, acid, and solvent resistance, enabling long-term safe operation in highly polluted or corrosive environments. The fully epoxy-cast insulation provides high sealing performance that isolates live parts from flammable gases, ensuring explosion-proof safety. In a retrofit project at the Maoming branch of China Petrochemical Corporation, a comprehensive upgrade of problem circuits using all-inorganic-mineral, fully insulated cast busway products saved 669,000 kWh of electricity per year and 541.5 kg of aluminum alloy profile per year, with an investment payback period of only 4 months.
(3) Rail Transit and Tunnel Engineering
Subway tunnels, high-speed rail power systems, and similar facilities demand extremely high stability for power equipment under vibration and humid conditions. Cast Busway can withstand mechanical shocks above 6G, ensuring safe operation amid the continuous vibration generated by moving trains. The product operates reliably in tunnel environments with long-term water immersion and high dust levels, and is widely used in rail transit traction substations and station power distribution systems.
(4) Nuclear Power and Electrical Facilities
Nuclear power plants, hydropower stations, thermal power plants, substations, and other power facilities demand extremely high safety ratings and reliability from power supply equipment. Cast busway products solve problems inherent in traditional cable connections used in nuclear power, such as high capacitance-to-ground current, high losses, high voltage drop, low current-carrying capacity, and short service life; customers report high reliability, long service life, low capacitance-to-ground current, and good seismic performance. The product is applicable to low- and medium-voltage power transmission and distribution systems in thermal, hydro, and nuclear power, with a maximum rated current of up to 6300A.
(5) Data Centers and Information Infrastructure
Data centers demand extremely high stability and reliability from power systems, while equipment is densely packed and space is precious. Cast Busway's volume is only 17% that of a traditional air-insulated busway, taking up little space and making on-site layout convenient — particularly suited to the compact wiring space of data center facilities. The product's strong electrical insulation performance effectively avoids short-circuit risk from humidity and dust, with insulation resistance reaching above 1000 MΩ. The modular design allows data centers to flexibly adjust power distribution schemes according to IT equipment layout; prefabricated modules reduce on-site labor by 40% with short commissioning times.
(6) Large Public Buildings and Commercial Complexes
Airport terminals, stadiums, convention centers, hospitals, and other large public buildings have strict requirements for power supply safety and continuity, and often face dense crowds and high fire-safety demands. Cast Busway's composite insulation material is halogen-free and releases no harmful gases at high temperatures; it is self-extinguishing and produces no toxic smoke in a fire, ensuring safe evacuation. The product can operate long-term in environments as cold as -40°C and is not limited by altitude, adapting to a wide range of climates and geographic conditions.
(7) Industrial Plants and Manufacturing Enterprises
Industrial enterprises in paper-making, machinery and electronics, and steel and metallurgy demand high reliability from power distribution equipment under dusty, humid, and high-temperature conditions. Cast Busway's fully enclosed structure effectively resists dust ingress, avoiding short-circuit faults caused by conductive dust accumulation. The product has high mechanical strength and impact resistance, with an impact rating as high as IK10, able to withstand accidental mechanical impacts in industrial environments. The product is widely used in shipbuilding, paper mills, power plants, substations, petrochemical plants, steel and metallurgical plants, machinery and electronics facilities, and large buildings.
(8) Coal Mines and Mining Sites
Underground coal mines and mining environments feature high dust, high humidity, and flammable gases, placing special demands on the explosion-proof and sealing performance of electrical equipment. Cast Busway's fully epoxy-cast structure provides high sealing performance that isolates live parts from flammable gases. The product can withstand a 6-joule mechanical impact and offers good explosion-proof performance, suitable for coal mines and other locations with strict safety requirements.
(9) Wastewater Treatment and Water Plants
Wastewater treatment plants, waterworks, and similar facilities operate long-term in high-humidity, moisture-laden environments where traditional metal-enclosed busways easily corrode. Cast Busway achieves an IP68 protection rating, allowing long-term submersion in water while providing stable power transmission. The composite insulation material has excellent anti-corrosion performance, effectively resisting attack from wastewater and chemical agents, ensuring long-term reliable equipment operation.
(10) New Energy and Renewable Energy
Photovoltaic power stations, wind farms, energy storage stations, and other new-energy projects are often located in coastal, desert, or plateau areas with harsh natural environments, demanding extremely high all-weather adaptability from electrical equipment. Cast Busway can operate normally at plateau altitudes of 5000 meters, with a temperature range covering -40°C to 120°C, adapting to all kinds of extreme climate conditions. The product's power density is 30% higher than traditional cable systems, meeting the high-power demands of large renewable-energy projects.
(11) Underground Engineering and Cable Trenches
Underground utility tunnels, cable trenches, civil air-defense projects, and similar facilities have narrow spaces, high humidity, and poor drainage conditions, and traditional busways are prone to moisture damage. Cast Busway can be buried underground with no altitude restriction and can operate reliably in long-term water-immersed environments. Inter-section joints are cast on site; once busway installation is complete, the system protection rating reaches IP68, making it suitable for harsh environments such as high-humidity outdoor areas and cable trenches. The metal-enclosure-free design prevents enclosure electrochemical corrosion, giving it a service life far exceeding traditional products.
The polyurethane-blended inorganic mineral epoxy resin copper busbar cast busway is a new type of power distribution device with no metal enclosure. It is suitable for AC 50Hz systems with a rated voltage below 1000V and a rated operating current from 400A to 6300A, for 50-60Hz three-phase four-wire and three-phase five-wire power supply and distribution systems. The product uses a sandwich-type, tightly laminated phase conductor design: high-performance composite insulation material is cast directly around the copper busbars to form a fully enclosed, air-gap-free monolithic structure with an IP68 protection rating, enabling reliable operation in extreme environments such as long-term water immersion, high dust, and strong corrosion. The product complies with the national standard GB/T 7251.6-2015 and is an ideal power distribution choice for shipbuilding, chemical processing, metallurgy, rail transit, data centers, nuclear power, marine engineering, and other applications with high safety requirements.
II. Core Structure
The polyurethane-blended inorganic mineral epoxy resin copper busbar cast busway uses a fully enclosed, integrally cast structure made of three core parts: high-purity copper busbar conductors, high-performance composite insulation material, and an integrally cast insulating protective layer.
For the conductor, high-purity electrical copper drawn from national-standard T2 electrolytic copper is used, with copper content no less than 99.90% and resistivity below 0.01777 Ω·mm²/m. The copper busbars use a fully rounded-edge "R-bar" design with tin plating along the full surface length, effectively enhancing oxidation and corrosion resistance and reducing contact resistance. Tin-plated joints reduce contact resistance by 15%, minimizing heat generation, and cut energy loss by up to 8% compared with unplated solutions. Busbar cross-section and length are designed to specific load requirements, ensuring stable operation under full-load conditions.
For the insulation system, the product is cast as a single piece from a composite insulation material combining polyurethane-blended inorganic minerals with epoxy resin. This composite insulation material is precisely formulated from epoxy resin, quartz sand, and various inert inorganic mineral materials according to a specific recipe and process, delivering superior electrical insulation performance, mechanical performance, and heat dissipation. The composite insulation material can contain 80% to 90% inorganic material, precisely proportioned with epoxy resin, curing agent, toughening agent, silane coupling agent, and other components, and is cured as a single piece through a vacuum mixing and casting process. The insulation material is halogen-free and releases no harmful gases when exposed to fire; it is self-extinguishing, rated Class A for fire resistance, with an F120 fire rating.
For the enclosure, the product has no metal enclosure — it is cast as a single piece from high-performance composite insulation material, eliminating air gaps and preventing enclosure electrochemical corrosion. The insulation material's coefficient of linear expansion is very close to that of copper, allowing it to expand and contract in sync with the copper busbars under temperature changes, effectively preventing insulation cracking and enhancing the thermal stability of the Busway system. The insulation material has a high thermal conductivity and good heat dissipation, formulated from a range of inert inorganic minerals and specialty epoxy resin using an optimal recipe and a special vacuum mixing and casting process to ensure good heat dissipation.
The product has a compact, modular design, with standard section lengths of up to 6 meters, greatly reducing the number of connection points, lowering overall system impedance by 15%, and significantly improving power transmission efficiency. The joints use a dual-locking method combining mechanical clamping and cast sealing, ensuring a reliable, maintenance-free connection.
III. Core Performance Features
Outstanding waterproof performance. The product is cast as a single piece from high-performance composite insulation material, offering excellent air-tightness and water-tightness with an IP68 protection rating. IP68 is the highest protection class, preventing dust ingress and enabling long-term reliable operation even under continuous water immersion. The product can operate submerged in water for extended periods or be buried underground, with no altitude restrictions. Inter-section joints are cast on site; once busway installation is complete, the system protection rating reaches IP68, making it suitable for harsh environments such as high-humidity outdoor areas and cable trenches.
Excellent fire resistance. The composite insulation material is self-extinguishing, rated Class A for fire resistance with an F120 fire rating; it can withstand flames of 950-1000°C for more than 90 minutes without circuit interruption, and the insulating resin is halogen-free, releasing no harmful gases at high temperatures. It meets the requirements of the 750°C three-hour burning test and is suitable for applications with strict fire-safety requirements. The product prevents flame spread under fire conditions without requiring a dedicated busway fire-barrier unit.
Outstanding corrosion resistance. Metal-enclosed busways cannot resist acid-rain corrosion, and corrosive gases and liquid splashes generated in chemical plants can damage electrical equipment. The epoxy resin casting compound used in Cast Busway has excellent anti-corrosion performance, effectively resisting attack from various chemicals. The cured synthetic resin has excellent alkali, acid, and solvent resistance and resists most molds, enabling long-term safe operation in highly polluted or corrosive environments. The product has passed a 96-hour salt spray test with no corrosion.
Reliable explosion-proof performance. The Busway system, cast entirely in epoxy resin, provides high sealing performance that isolates live parts from flammable gases, ensuring safe operation in flammable and explosive environments. The product can withstand a 6-joule mechanical impact, ensuring safe use, and offers good explosion-proof performance. It can also withstand mechanical shocks above 6G, meeting the requirements of harsh operating conditions.
Strong electrical insulation performance. The excellent casting process creates a seamless bond between the insulation layer and the conductor, avoiding partial discharge caused by air gaps and improving insulation strength by more than 30%. The product's normal insulation resistance can reach above 1000 MΩ, effectively avoiding short-circuit risks caused by humidity or dust. The air-gap-free design eliminates the chimney effect; once installed and running, the product is maintenance-free for life.
Efficient heat dissipation and excellent temperature-rise control. The composite insulation material is formulated from a range of inert inorganic minerals and specialty epoxy resin using an optimal recipe and special vacuum mixing and casting process, giving it high thermal conductivity and good heat dissipation. The composite insulation material has a thermal conductivity of about 0.2 W/m·K, dissipating heat effectively; under full-load operation, its operating temperature is 20°C lower than standard PVC-insulated busways. The unique composite insulation material formulation ensures the thermal expansion coefficient of the insulation matches that of the conductor, effectively preventing insulation cracking.
High mechanical strength and impact resistance. The cured composite insulation material has high mechanical strength, wear resistance, and impact resistance, giving the product an impact-resistance rating as high as IK10. The fully enclosed cast structure gives the product excellent dynamic thermal stability and an extremely low fire load. The product has a compact design with a small footprint — only 17% the volume of a traditional air-insulated busway — taking up less space and making on-site layout convenient.
All-weather adaptability. The product's use is not limited by altitude; it can operate long-term in environments as cold as -40°C without the insulating resin cracking, and can be used long-term indoors or outdoors in the highest pollution level (Level 4) environment. Its temperature range covers -40°C to 120°C, suiting all types of climate conditions worldwide.
Significant energy savings. Under the same operating conditions and current density, current-carrying capacity is 10% to 20% greater than traditional busways; for the same rating, volume is 1/2 (low voltage) to 1/10 (medium voltage) smaller. Energy savings can reach 8% to 30%, and conductor material usage is reduced by 8% to 20% compared with traditional busways under the same conditions.
IV. Core Manufacturing Process Features
The polyurethane-blended inorganic mineral epoxy resin copper busbar cast busway employs a number of advanced manufacturing technologies to ensure product precision, reliability, and consistency.
Precise formulation and raw material control. The composite insulation material is precisely formulated from epoxy resin, polyurethane, and various inert inorganic mineral materials according to a specific recipe and process. In a typical casting compound ratio, inorganic material accounts for about 80-84 parts, combined epoxy resin about 21-28 parts, toughening agent about 11-14 parts, and curing agent about 13-15 parts, plus appropriate amounts of silane coupling agent, peroxide initiator, and other additives. Key raw materials such as epoxy resin and curing agent are imported from Europe for an absolute quality advantage, and conductors are sourced from qualified manufacturers with performance exceeding national standards, under strict inspection and control procedures.
Imported German vacuum casting equipment. Jiuwei Busway Technology uses original imported German vacuum casting equipment featuring precise metering and vacuum mixing systems; the entire casting, batching, and vacuum-mixing process is completed automatically by the equipment, effectively avoiding product quality issues caused by human error. The imported German vacuum casting and mixing equipment allows continuous, digitally controlled metering and uniform mixing of raw materials, stirred under vacuum conditions.
Strict production environment control. Cast busway production has strict environmental and process parameter requirements; temperature and humidity must be controlled within specific ranges. Jiuwei Busway Technology's casting workshop is equipped with an air-conditioning system that strictly controls temperature and humidity, effectively ensuring stable and consistent product quality. Temperature, pressure, and time parameters must be strictly controlled during production to ensure the insulation layer is free of bubbles and defects.
Comprehensive quality inspection system. Quality inspection includes electrical performance tests (such as withstand-voltage and insulation resistance measurement), mechanical strength tests, and environmental adaptability verification. The cast busway system can withstand a 3750V power-frequency withstand-voltage test for one minute with no breakdown or flashover. A contact resistance tester is used to control joint contact resistance, ensuring joint temperature rise meets standard requirements.
Modular design and factory prefabrication. Before leaving the factory, the product is prefabricated into straight sections, corner sections, T-sections, and end caps according to specific project layout requirements, making on-site installation convenient. Prefabricated modules reduce on-site labor by 40%, require no secondary waterproofing, and shorten commissioning time. Standard section lengths of up to 6 meters greatly reduce the number of connection points.
On-site joint casting process. Inter-section joints are cast on site — the joint location is the area most prone to faults. On-site connections use a contact resistance tester to control contact resistance and ensure controlled joint temperature rise. The insulation material is mixed on site using small vacuum equipment, fully ensuring joint performance. Joints use a dedicated Y-type waterproof connector for reliable, convenient connection.
V. Diverse Application Scenarios
Thanks to its comprehensive performance in waterproofing, fire resistance, corrosion resistance, explosion protection, high insulation, and high mechanical strength, the polyurethane-blended inorganic mineral epoxy resin copper busbar cast busway is widely used in applications with stringent requirements for the continuity and safety of power supply.
(1) Shipbuilding and Marine Engineering
Ships, offshore platforms, and port facilities operate in marine environments with high salt spray, high humidity, and strong corrosion, demanding extremely strict corrosion resistance and waterproofing from electrical equipment. The epoxy resin casting compound in Cast Busway offers excellent anti-corrosion performance, effectively resisting seawater salt-spray corrosion. Its IP68 protection rating withstands wave impact and long-term submersion for safe use. The product can withstand salt corrosion and vessel vibration shock, and is widely used in shipbuilding, docks, offshore wind farms, and coastal industrial zones.
(2) Petrochemical and Metallurgical Industries
Chemical plants, oil refineries, steel mills, and similar facilities contain large amounts of corrosive gases and liquids and flammable/explosive environments, demanding extremely high safety and reliability from power distribution equipment. Cast Busway's composite insulation material offers excellent alkali, acid, and solvent resistance, enabling long-term safe operation in highly polluted or corrosive environments. The fully epoxy-cast insulation provides high sealing performance that isolates live parts from flammable gases, ensuring explosion-proof safety. In a retrofit project at the Maoming branch of China Petrochemical Corporation, a comprehensive upgrade of problem circuits using all-inorganic-mineral, fully insulated cast busway products saved 669,000 kWh of electricity per year and 541.5 kg of aluminum alloy profile per year, with an investment payback period of only 4 months.
(3) Rail Transit and Tunnel Engineering
Subway tunnels, high-speed rail power systems, and similar facilities demand extremely high stability for power equipment under vibration and humid conditions. Cast Busway can withstand mechanical shocks above 6G, ensuring safe operation amid the continuous vibration generated by moving trains. The product operates reliably in tunnel environments with long-term water immersion and high dust levels, and is widely used in rail transit traction substations and station power distribution systems.
(4) Nuclear Power and Electrical Facilities
Nuclear power plants, hydropower stations, thermal power plants, substations, and other power facilities demand extremely high safety ratings and reliability from power supply equipment. Cast busway products solve problems inherent in traditional cable connections used in nuclear power, such as high capacitance-to-ground current, high losses, high voltage drop, low current-carrying capacity, and short service life; customers report high reliability, long service life, low capacitance-to-ground current, and good seismic performance. The product is applicable to low- and medium-voltage power transmission and distribution systems in thermal, hydro, and nuclear power, with a maximum rated current of up to 6300A.
(5) Data Centers and Information Infrastructure
Data centers demand extremely high stability and reliability from power systems, while equipment is densely packed and space is precious. Cast Busway's volume is only 17% that of a traditional air-insulated busway, taking up little space and making on-site layout convenient — particularly suited to the compact wiring space of data center facilities. The product's strong electrical insulation performance effectively avoids short-circuit risk from humidity and dust, with insulation resistance reaching above 1000 MΩ. The modular design allows data centers to flexibly adjust power distribution schemes according to IT equipment layout; prefabricated modules reduce on-site labor by 40% with short commissioning times.
(6) Large Public Buildings and Commercial Complexes
Airport terminals, stadiums, convention centers, hospitals, and other large public buildings have strict requirements for power supply safety and continuity, and often face dense crowds and high fire-safety demands. Cast Busway's composite insulation material is halogen-free and releases no harmful gases at high temperatures; it is self-extinguishing and produces no toxic smoke in a fire, ensuring safe evacuation. The product can operate long-term in environments as cold as -40°C and is not limited by altitude, adapting to a wide range of climates and geographic conditions.
(7) Industrial Plants and Manufacturing Enterprises
Industrial enterprises in paper-making, machinery and electronics, and steel and metallurgy demand high reliability from power distribution equipment under dusty, humid, and high-temperature conditions. Cast Busway's fully enclosed structure effectively resists dust ingress, avoiding short-circuit faults caused by conductive dust accumulation. The product has high mechanical strength and impact resistance, with an impact rating as high as IK10, able to withstand accidental mechanical impacts in industrial environments. The product is widely used in shipbuilding, paper mills, power plants, substations, petrochemical plants, steel and metallurgical plants, machinery and electronics facilities, and large buildings.
(8) Coal Mines and Mining Sites
Underground coal mines and mining environments feature high dust, high humidity, and flammable gases, placing special demands on the explosion-proof and sealing performance of electrical equipment. Cast Busway's fully epoxy-cast structure provides high sealing performance that isolates live parts from flammable gases. The product can withstand a 6-joule mechanical impact and offers good explosion-proof performance, suitable for coal mines and other locations with strict safety requirements.
(9) Wastewater Treatment and Water Plants
Wastewater treatment plants, waterworks, and similar facilities operate long-term in high-humidity, moisture-laden environments where traditional metal-enclosed busways easily corrode. Cast Busway achieves an IP68 protection rating, allowing long-term submersion in water while providing stable power transmission. The composite insulation material has excellent anti-corrosion performance, effectively resisting attack from wastewater and chemical agents, ensuring long-term reliable equipment operation.
(10) New Energy and Renewable Energy
Photovoltaic power stations, wind farms, energy storage stations, and other new-energy projects are often located in coastal, desert, or plateau areas with harsh natural environments, demanding extremely high all-weather adaptability from electrical equipment. Cast Busway can operate normally at plateau altitudes of 5000 meters, with a temperature range covering -40°C to 120°C, adapting to all kinds of extreme climate conditions. The product's power density is 30% higher than traditional cable systems, meeting the high-power demands of large renewable-energy projects.
(11) Underground Engineering and Cable Trenches
Underground utility tunnels, cable trenches, civil air-defense projects, and similar facilities have narrow spaces, high humidity, and poor drainage conditions, and traditional busways are prone to moisture damage. Cast Busway can be buried underground with no altitude restriction and can operate reliably in long-term water-immersed environments. Inter-section joints are cast on site; once busway installation is complete, the system protection rating reaches IP68, making it suitable for harsh environments such as high-humidity outdoor areas and cable trenches. The metal-enclosure-free design prevents enclosure electrochemical corrosion, giving it a service life far exceeding traditional products.
VI. Summary of Product Advantages
The polyurethane-blended inorganic mineral epoxy resin copper busbar cast busway offers the following core advantages:
Outstanding waterproof performance, IP68 protection rating; can operate long-term in water or be buried underground, with no altitude restriction.
Excellent fire resistance, Class A fire rating, F120 fire rating; can withstand flames of 950-1000°C for more than 90 minutes; halogen-free and releases no harmful gases at high temperatures.
Outstanding corrosion resistance; resists acids, alkalis, oils, liquids, and salt spray corrosion; passed a 96-hour salt spray test.
Reliable explosion protection; fully epoxy-cast to isolate live parts from flammable gases; withstands 6-joule mechanical impact and vibration above 6G.
Strong electrical insulation performance; insulation layer bonds seamlessly to the conductor, improving insulation strength by more than 30%, with insulation resistance above 1000 MΩ.
Efficient heat dissipation with high thermal conductivity; operating temperature under full load is 20°C lower than standard PVC-insulated busways.
High mechanical strength, IK10 impact rating; volume only 17% that of a traditional air-insulated busway, taking up little space.
All-weather adaptability, temperature range -40°C to 120°C; usable long-term indoors or outdoors in the highest pollution level (Level 4) environment.
Significant energy savings, 8% to 30% energy savings rate; current-carrying capacity 10% to 20% greater than traditional busways; volume 1/2 to 1/10 that of same-rated traditional busways.
Maintenance-free design; once installed and running, the product requires no maintenance for life; prefabricated modules reduce on-site labor by 40%.
Superior aging resistance, with an aging-resistant service life of up to 60 years; service life exceeds 50 years under harsh conditions, and insulation aging life exceeds 50 years.