Busbar Waste Calculator

Every saw cut and every punched hole throws away metal. This free tool tells you exactly how much — in kilograms and in money, at live copper & aluminum prices.

Blade kerf loss per cut

The kerf — the slot a saw blade eats — is estimated at 1.5% of the blade diameter (never less than 0.5 mm), multiplied by your busbar cross-section. A 300 mm blade on a 100×10 mm copper bar wastes roughly 40 grams of copper on every single cut.

Punch-out waste

Every punched hole removes a slug of metal: hole area × busbar thickness. The calculator converts it to weight with the exact alloy density and prices it at the live market rate — so you can quote scrap loss honestly.

Try it now

The waste calculator is part of the free Busbar Calculator — create an account (10 seconds) and it unlocks together with saved history and configuration compare.

Building a whole panel? Try the EPLAN panel cost calculator →