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Busbar Inspection and Maintenance

MET Group Carry Out Busbar Inspections Live Under Full Load

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Busbar inspection and maintenance is often overlooked but is highly effective in keeping critical systems running. We offer full in-depth inspection and maintenance on all existing busbar systems.

We carry fully calibrated equipment for inspection, service, and electrical test/diagnostics of busbar performance issues. Many our clients have benefitted from this cost-preventing service.  This has lead to the diagnosis and correction of major faults before catastrophic failure occurred on existing installations.

Busbars play a crucial role in electrical distribution systems, providing a common connection point for multiple circuits. Regular testing and maintenance of busbars are essential to ensure the reliability and safety of the electrical system. Here are key aspects of busbar testing and maintenance: –

  1. Visual Inspection:

    • Perform a visual inspection of the busbars to check for signs of physical damage, corrosion, loose connections, or overheating.

    • Ensure that the busbar supports and insulators are in good condition.

  2. Tightness of Connections:

    • Check the tightness of all connections, including busbar-to-busbar connections and connections to other electrical components.

    • Loose connections can lead to increased resistance, heating, and potential failure

  3. Thermographic Imaging:

    • Use thermal imaging to identify any abnormal temperature patterns on the busbars. Hot spots may indicate loose connections, imbalances in current distribution, or other issues.

    • Address any anomalies detected during thermal imaging to prevent overheating and potential failures.

  4. Insulation Resistance Test:

    • Perform an insulation resistance test to assess the insulation integrity of the busbars. This test helps identify any insulation breakdown or contamination.

    • Regular insulation resistance testing is crucial to prevent electrical leakage and ensure the safety of the system.

  5. Contact Resistance Test:

    • Conduct a contact resistance test to ensure that the electrical contacts at the busbar joints have low resistance. High contact resistance can lead to increased heat generation and inefficiencies.

    • Clean and tighten connections as needed to maintain low contact resistance.

  6. Ultrasonic Inspection:

    • Detection of Internal Defects, Thickness Measurement, Crack Detection, loose joints.

    • Ultrasonic testing is effective in identifying cracks on the surface or within the material of the busbar. Early detection of cracks is crucial for preventing.

  7. Dielectric Strength Test:

    • Perform a dielectric strength test to check the insulation properties of the busbars under high voltage conditions.

    • This test helps ensure that the insulation can withstand the specified voltage stress without breakdown.

  8. Mechanical Inspection:

    • Check the mechanical condition of busbar supports, isolators, and any moving parts. Lubricate components as necessary to maintain proper operation.

    • Verify that the busbar system can be operated safely and smoothly.

  9. Protective Coating Inspection:

    • Inspect any protective coatings on the busbars for signs of wear or damage. Protective coatings help prevent corrosion and ensure the longevity of the busbars.

    • Repair or replace coatings as needed.

  10. Corrosion Protection:

    • Implement corrosion protection measures, especially in environments prone to corrosion. This may include the application of corrosion-resistant coatings or the use of corrosion inhibitors.

  11. Documentation and Recordkeeping:

    • Maintain accurate records of busbar inspections, tests, and maintenance activities. Documentation helps track the history of the busbars and supports future troubleshooting.

Regular and proactive testing and maintenance of busbars are essential to prevent unplanned downtime, ensure system reliability, and enhance the overall safety of the electrical distribution system. Always follow safety procedures and manufacturer recommendations when conducting tests and maintenance activities.


Many of these faults are often blamed on loading or harmonics in the building.  They can lead to catastrophic failure if not found by routine electrical checks

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Here is an example of a fault found.

This is a busbar connection arcing identified four meters up in a commercial building.

This serious fault was identified while carrying out our airborne ultrasonic test.


Talk to us

Contact us today and we can discuss your project needs.

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