Design Your Track Busway System
How to Design a Flexible, Scalable Track Busway Layout
USA TrackBusway makes it simple to design overhead power that adapts as fast as your facility changes. This guide shows the key steps engineers follow when planning a Track Busway layout — from defining circuits to choosing feed points, laying out ROWs/GRIDs, and planning PowerDrops.
Track Busway systems install quickly, reduce wiring, eliminate conduit changes, and support continuous plug-in access anywhere along the run. Use the steps below to configure a layout that is efficient today and easily expandable tomorrow.
Start Your Track Busway Layou
Send us your panel schedule, floor plan, or equipment list. Our team will prepare a layout showing feeds, ROWs/GRIDs, PowerDrops, and recommended circuit configuration.
Step 1 — Select Your Circuit Type
Selecting the correct circuit type ensures the busway can support all equipment along the run.
Track Busway supports:
40A per phase (standard)
225A per phase (mission-critical)
Optional IG + 200% neutral
Step 2 — Choose Your Physical Layout (ROW, GRID, or RECTANGLE)
Track Busway layouts follow your workflow.
Ideal for:
- Assembly lines
- Conveyor paths
- Linear workstations
- Production environments
Advantages:
- Minimal feeds
- Easy future lengthening
- PowerDrops can be moved anywhere along the run
Ideal for:
- Labs and R&D
- Automotive bays
- Manufacturing cells
- Worktable clusters
Advantages:
- Continuous power across multiple directions
- Supports lighting + power in the same overhead structure
- Excellent for multi-operator environments
Ideal for:
- Crossing an aisle
- Connecting separated work zones
- Feeding power across open areas
Step 3 — Determine Feed Locations
Track Busway does not restrict feed points like older fixed-tap busway systems. You can place feeds at:
Panelboard ‘A’ may be 120/208V or 277/480V depending on building service.
Available: 208/480V
Line to Neutral Available: 120/277V
Line to Line Available: 1Ph-208V or 1Ph-480V
Available: 208/480V
- The end of a ROW
- The center of a GRID
- A branch point feeding two directions
- A midpoint where loads are balanced
- General guidelines:
- Each standard run supports up to 40A per phase from a single feed.
- If loads exceed 40A, use:
- Feed-left / Feed-right strategy
- Double-deck (2x3-pole) layouts to split loads
- Junction-box splitters allow one feed to serve two directions per NEC tap rules.
Steel Track Busway combines the strength of steel strut, the continuous plug-in flexibility of commercial lighting track, and the electrical performance of busway. The open-slot design allows PowerDrops, lighting fixtures, and data modules to plug in anywhere — without predetermined tap windows or rewiring.
Step 4 — Plan Your Plug-In PowerDrops
PowerDrops are added last, after equipment locations are known — but they should be planned early.
Step 5 — Validate Loads & Future Expansion
Before finalizing, confirm:
Modular COMPONENTs
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View RUNs
RUNsThe parts needed for a complete run of Steel Track Busway.
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View CROSSOVERs
CROSSOVERsThe mechanical connector needed for intersecting runs of Steel Track Busway.
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View JUMPERs
JUMPERsThe electrical connector needed for intersecting runs of Steel Track Busway.
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View FEEDs
FEEDsThe feed needed for powering Steel Track Busway.
Ready to Move Forward?
Let us help finalize your Track Busway layout.
WATCH: Movable TrackBusway Lengths — Adaptable Layouts Made Easy
As equipment layouts change, sections of busway can be repositioned—without conduit, rewiring, or electricians. This video shows how Track Busway adapts with your facility using a modular bridge kit and flexible PowerDrops.
Track Busway supports evolving workspaces with a sustainable, plug-in power system that reduces waste, speeds up changes, and keeps overhead power exactly where it’s needed.
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