Correct torque creates metal-to-metal contact pressure while avoiding thread damage. For copper busbar joints (indoor switchgear, clean dry conditions): For aluminum busbar joints: Reduce torque by 15–20% compared to copper (softer metal, creeps under load)Preventing hot joints requires three elements executed correctly: proper surface preparation (removing oxidation and achieving metal-to-metal contact), correct torque application (creating sufficient contact pressure without damaging threads), and ongoing thermal monitoring (catching deterioration. In this new edition the calculation of current-carrying capacity has been greatly simplified by the provision of exact formulae for some common busbar configurations and graphical methods for others. Other sections have been updated and modified to reflect current practice. Copper Development. Instead, proper torque, contact pressure, and joint design govern contact resistance and long-term reliability inside an industrial electrical enclosure. This article explains, from an engineering and enclosure-manufacturer perspective, why torque matters more than overlap area. The elastic washers placed on the external sides of the connections and busbars help ensure for. It is usually necessary to joint busbars on site during installation and this is most easily accomplished by bolting bars together or by welding. For long and reliable service, joints need to be carefully made with controlled torque applied to correctly sized bolts. Each splice plate is attached with.