The coupled field, Magnetic-thermal-structural analysis has been carried out for 230 kV bare and nano Fe coated busbar. The integrated coupled field analytical equations were developed by using electrical parameters to predetermine the temperature rise and mechanical stress. The finite element method software ANSYS APDL commercial package has been used for simulation analysis with magneto-thermal-structural sequential weak coupling methods. The 6061-T6 hollow aluminium busbar size of 1 m length and 8 mm thickness with the load current of 1000 A was modelled and the magnetic field effect was analysed through magnetostatic solver. From the analysis, it was inferred that the nano iron coated busbar diminishes the magnetic field around 80% in the vicinity areas. The magnetic field reduction is achieved by high conductivity and high permeability of the material. It also reduces the rise of temperature by 4 °C with the property of high thermal conductivity, thus reduces the thermal flux by 50 W m−2. Thermal dependent mechanical stress is decreased by 35% for coated conductor compare with the bare conductor. Due to the thermal expansion coefficient, the coated material aid to protect the busbar against the mechanical stress. The simulation results were analyzed and compared with the analytical results. The nano coated conductor exhibit the low electromagnetic pollution in the environment by reducing the electromagnetic field and temperature rise.