Neutral Bar Sizes, Ways and Current Ratings
Neutral bars are available in many different sizes, ways, hole quantities and current ratings. For distribution boards, consumer units, DB boxes, breaker panels and electrical panels, choosing the right neutral bar size is important for safe wiring, easy installation and reliable electrical connection.
Carsai manufactures custom neutral bars for electrical panel builders, distribution board suppliers and OEM electrical equipment manufacturers. Our neutral bars can be produced in different lengths, hole numbers, screw sizes, materials, plating options and current ratings according to customer drawings, samples or application requirements.
Whether you need a neutral bar 12 way, 10 way neutral bar, 18 hole neutral bar, neutral bar 100A, 200A neutral bar, 400A neutral bar, neutral bar 16mm, 25mm neutral bar or 35mm neutral bar, we can support custom production based on your panel design.
What Does “Way” Mean in a Neutral Bar?
In neutral bar descriptions, “way” usually refers to the number of wire connection positions. For example, a 6 way neutral bar normally has six terminal positions, while a 12 way neutral bar has twelve connection positions.
Common options include 4 way neutral bar, 6 way neutral bar, neutral bar 7 way, neutral bar 8 way, 10 way neutral bar, neutral bar 12 way, 15 way neutral bar, 18 way neutral bar, 20 way neutral bar, 24 way neutral bar and 36 way neutral bar.
In some product descriptions, buyers may also see terms such as 24 pole neutral bar or 48 pole neutral bar. In many cases, “pole” is used similarly to “way,” but the exact meaning should be checked based on the drawing or product structure.
For OEM distribution board manufacturers, the required number of ways depends on the number of circuits inside the panel. A small consumer unit may only need a 6 hole neutral bar or 8 way neutral bar, while a larger distribution board may need a 24 way or 36 way neutral bar.
Neutral Bar Holes and Terminal Positions
Neutral bars are often described by the number of holes. For example, a neutral bar 12 hole or 18 hole neutral bar means the bar has 12 or 18 wire connection holes.
The hole number is not always the same as the way number in every design. Some neutral bars may have side-entry wire holes and top screws. Some may have two rows of holes. Some may include mounting holes in addition to terminal holes.
Before production, it is important to confirm:
Number of wire holes
Number of screws
Mounting hole quantity
Hole diameter
Thread size
Hole spacing
Wire entry direction
For custom neutral bars, Carsai can manufacture according to the exact hole layout required by the customer’s electrical panel or distribution board.
Common Neutral Bar Sizes
Neutral bar sizes vary depending on application, current rating, wire size and panel space. Small consumer units may use compact neutral bars, while larger electrical panels or panelboards may require longer and thicker neutral bars.
Common size-related search terms include neutral bar 10mm, neutral bar 16mm, neutral bar 25mm, neutral bar 35mm, 16mm neutral bar, 25mm neutral bar and 35mm neutral bar.
In many cases, these numbers may refer to wire capacity, cable size, bar size or terminal size, depending on the market. For example, a neutral bar 16mm may refer to a neutral bar suitable for 16mm² wires, while neutral bar 35mm may refer to larger cable capacity.
Because product descriptions can vary by country, it is always better to confirm the actual drawing, wire size and terminal hole diameter before ordering.
Current Ratings: 60A, 63A, 100A, 200A, 250A and 400A
Neutral bars are also commonly described by current rating. Common search terms include neutral bar 60A, neutral link bar 60A, 60A neutral bar, neutral bar 63A, 63A neutral bar, 63 amp neutral bar, neutral bar 100A, neutral link bar 100A, 100A neutral bar and 100 amp neutral bar.
For larger electrical systems, buyers may need neutral bar 200A, 200A neutral bar, 200 amp neutral bar, neutral bar 250A, 250A neutral bar, 250 amp neutral bar, neutral bar 400A, 400A neutral bar or 400 amp neutral bar.
The current rating depends on material, cross-sectional area, screw size, contact surface, wire size and installation environment. A neutral bar should not be selected only by the number of holes. A 12 way neutral bar may have a lower or higher current rating depending on its material and dimensions.
For custom neutral bars, the required current rating should be confirmed before production so the bar size and material can match the electrical system.
6 Way, 8 Way, 10 Way and 12 Way Neutral Bars
Small and medium distribution boards often use 6 way, 8 way, 10 way or 12 way neutral bars. These are common in consumer units, DB boxes, small breaker panels and compact electrical distribution systems.
A neutral bar 6 way or 6 hole neutral bar is suitable for smaller panels with fewer circuits. A neutral bar 8 way or 8 way neutral bar provides more connection positions while still keeping a compact size. A neutral bar 10 way or 10 way neutral bar is common for medium panels. A neutral bar 12 way or 12 way neutral bar is widely used in distribution boards with more branch circuits.
Neutral link bar 10 way and neutral link bar 12 way are also common terms in some markets. These products are used to link multiple neutral conductors through one conductive bar.
Carsai can customize these neutral bars with different hole spacing, screw sizes, plating and mounting structures based on customer requirements.
18 Way, 20 Way, 24 Way and Larger Neutral Bars
Larger distribution boards and panelboards may require more terminal positions. Common options include 18 way neutral bar, 18 hole neutral bar, 20 way neutral bar, 24 way neutral bar, 24 pole neutral bar, 36 way neutral bar and 48 pole neutral bar.
These longer neutral bars are often used in bigger electrical panels, commercial distribution boards and industrial control cabinets. They allow many neutral conductors to be connected in one organized location.
For larger neutral bars, straightness, hole spacing and plating quality become more important. A long neutral bar must fit the panel layout accurately. If the hole spacing or length is wrong, assembly may be difficult.
Custom manufacturing is useful when the panel manufacturer needs a specific number of ways, special mounting holes or a non-standard length.
Material Options for Neutral Bars
Neutral bars are commonly made from brass or copper.
Brass neutral bars are widely used because brass has good mechanical strength and strong thread-holding performance. It is suitable for screw terminal structures and repeated wire locking. Many consumer unit neutral bars, DB neutral bars and electrical panel neutral bars are made from brass.
Copper neutral bars provide better electrical conductivity and may be selected for higher current requirements. A copper neutral bar or neutral copper busbar may be used when lower resistance or higher current capacity is required.
For most standard distribution board applications, brass is practical and cost-effective. For higher-performance electrical systems, copper may be preferred.
Carsai can manufacture both brass and copper neutral bars according to customer drawings or samples.
Surface Finish Options
Neutral bars are often plated to improve appearance and corrosion resistance. Common surface finishes include nickel plating, tin plating, bare brass and bare copper.
Nickel-plated brass neutral bars are common because they have a bright silver appearance and good oxidation resistance. Tin-plated copper neutral bars are also common, especially when the customer needs improved electrical contact and corrosion protection.
For product descriptions, if the exact finish is not confirmed, “plated brass neutral bar” is a safe term. If confirmed, it can be written as nickel-plated brass neutral bar or tin-plated copper neutral bar.
The surface finish should be selected according to the working environment, customer standard and electrical contact requirement.
How to Choose the Right Neutral Bar Size
To choose the right neutral bar, buyers should consider the number of circuits, wire size, current rating, panel space and installation method.
A small consumer unit may only need a 6 way neutral bar or 8 way neutral bar. A larger DB box may need a 12 way, 18 way or 24 way neutral bar. A commercial panelboard may require a longer neutral bar with higher current capacity.
The wire size is also important. If the wires are larger, the terminal holes and screws must also be larger. A neutral bar 16mm may not be suitable if the actual conductor size is much larger. For 25mm or 35mm wire applications, the terminal design must provide enough space and clamping force.
Current rating should also match the system requirement. A 60A neutral bar and a 400A neutral bar cannot be designed with the same material size and contact structure.
Custom Neutral Bar Manufacturing
Carsai supports custom neutral bar manufacturing for different electrical panel and distribution board applications.
Common custom options include:
Material: brass or copper
Surface finish: nickel plating, tin plating or bare material
Number of ways: 4 way, 6 way, 8 way, 10 way, 12 way, 18 way, 24 way or custom
Current rating: 60A, 63A, 100A, 200A, 250A, 400A or custom
Wire capacity: 10mm², 16mm², 25mm², 35mm² or custom
Hole diameter and thread size
Screw type and screw quantity
Mounting hole position
Overall length, width and thickness
Packaging requirement
We can manufacture according to drawings, samples or clear product photos with dimensions.
Information Needed for Quotation
To quote a custom neutral bar, the following information is helpful:
Required number of ways or holes
Current rating
Wire size or cable size
Material requirement
Surface finish
Overall dimensions
Hole diameter and thread size
Screw type
Mounting hole requirement
Application, such as consumer unit, DB box, distribution board or electrical panel
Drawing, sample photo or reference product
Order quantity and packaging requirement
If the buyer does not know the exact current rating, a drawing and application information can help us review the structure first.
Related Custom Terminal Bar Solutions
For a broader overview of custom copper and brass terminal solutions, including neutral bars, grounding terminal bars, earth terminal bars, busbar terminal blocks, high current terminal blocks and power distribution terminal blocks, visit our Custom Copper & Brass Busbar Terminal Blocks page.
Carsai also manufactures brass neutral bars, grounding terminal bars, DIN rail neutral busbars, screw terminal bars, copper terminal busbars and custom electrical terminal block parts for OEM applications.
Custom Neutral Bars from Carsai
Carsai manufactures custom neutral bars in different sizes, ways and current ratings for consumer units, DB boxes, distribution boards, electrical panels, breaker panels and panelboards.
Whether you need neutral bar 12 way, neutral bar 10 way, neutral bar 12 hole, 18 way neutral bar, 24 way neutral bar, 100A neutral bar, 200A neutral bar, 250A neutral bar, 400A neutral bar, 16mm neutral bar, 25mm neutral bar or 35mm neutral bar, we can support custom production based on your drawings, samples or specifications.
Send us your drawing, sample photo or basic requirements, and we will help review the design and provide a suitable manufacturing solution for your electrical panel project.
