Abstract: Electric bus bar insulating coatings are calibrated to withstand long term outdoor exposure without failure. Manufacturing samples of the coating material are evaluated at the coating manufacturing site prior to shipment to the bus bar manufacturer. Bus bar samples coated with the material are suspended within a heated water bath and subjected to several hundred volt-amperes. The thickness of the coating is predetermined to provide accurate qualifying data for each coating sample within a reasonable time frame. Coating compositions that qualify are then applied to electric bus bar conductors by the bus bar manufacturer.