Custom Bonding Bars: Sizes, Hole Patterns & Mounting Options
Why Bonding Bars Are Often Custom-Made
Bonding bars are rarely standard parts.
Different cabinets, racks, and enclosures require custom bonding bars to ensure proper placement, short bonding paths, and easy installation.
Customization improves:
- Installation efficiency
- Electrical performance
- System safety
1. Bonding Bar Sizes & Dimensions
Custom bonding bar dimensions are defined by:
- Available installation space
- Number of bonding connections
- Mechanical strength requirements
Typical customization includes:
- Length (short bars for cabinets, longer bars for racks)
- Thickness and width
- Edge finishing for safety and handling
2. Hole Patterns & Stud Layout
Hole pattern design directly affects usability and reliability.
Common options:
- Through-holes for bonding conductors
- Threaded holes (M4, M5, M6, M8, etc.)
- Studs for fast connection and repeated use
Precise hole spacing ensures:
- Easy access for tools
- Consistent conductor layout
- Secure electrical contact
3. Mounting Options for Bonding Bars
Bonding bars can be mounted using different methods depending on system design:
- Direct mounting to metal surfaces
- Mounting with brackets or base plates
- Insulated mounting (where required by design)
Mounting position is usually chosen to minimize bonding conductor length.
4. Material & Surface Finish Considerations
Custom bonding bars are commonly made from:
- Copper
- Tin-plated copper
Tin plating is preferred for:
- Corrosion resistance
- Stable long-term contact
- Telecom and outdoor applications
5. Manufacturing Considerations
High-quality custom bonding bars require:
- Accurate CNC drilling and tapping
- Flatness control
- Clean surface finish
- Consistent plating quality
At CARSAI Precision Parts, bonding bars are produced using CNC machining and stamping, ensuring repeatable quality for custom designs.
📩 Contact Us
If your project requires custom bonding bars with specific sizes, hole patterns, or mounting methods, we’re ready to help.
👉 Contact us to discuss drawings, specifications, and production quantities.
