CROSS-SECTIONAL DIMENSION TOLERANCES –
EXTRUDED WIRE, ROD, BAR AND PROFILES

Unspecified Dimension Tolerance to follow AA Standards
Dimension
(mm)
Solid Hollow
5.01-15mm
Hollow
15.01-30mm
Hollow
30.01-60mm
Hollow
60.01-100mm
Hollow
100.01-150mm
Hollow
150.01-200mm
0.00-3.20 ± 0.15 ± 0.25 ± 0.30
3.21-6.30 ± 0.18 ± 0.30 ± 0.36 ± 0.41
6.31-12.50 ± 0.20 ± 0.36 ± 0.41 ± 0.46 ± 0.50
12.51-20.00 ± 0.23 ± 0.41 ± 0.46 ± 0.50 ± 0.56
20.01-25.00 ± 0.25 ± 0.46 ± 0.50 ± 0.56 ± 0.64 ± 0.76
25.01-40.00 ± 0.30 ± 0.54 ± 0.58 ± 0.66 ± 0.76 ± 0.88
40.01-50.00 ± 0.36 ± 0.60 ± 0.66 ± 0.78 ± 0.92 ± 1.05 ± 1.25
50.01-100.00 ± 0.60 ± 0.86 ± 0.96 ± 1.20 ± 1.45 ± 1.70 ± 2.05
100.01-150.00 ± 0.86 ± 1.10 ± 1.25 ± 1.65 ± 2.00 ± 2.40 ± 2.80
150.01-200.00 ± 1.10 ± 1.35 ± 1.55 ± 2.10 ± 2.50 ± 3.05 ± 3.55

FLATNESS –EXTRUDED BAR, SOLID
PROFILES AND SEMIHOLLOW PROFILES

Minimum Thickness of Metal Forming the Surface  Width (mm)
(mm) 0-150 150.01-200 200.01-250
0.00-3.20 0.004 0.006 0.010
3.21-4.00 0.004 0.006 0.008
4.01-5.00 0.004 0.006 0.007
5.01-6.30 0.004 0.006 0.006
6.31-8.00 0.004 0.006 0.006
8.01-12.50 0.004 0.004 0.006
12.51-20.00 0.004 0.004 0.006
20.01-25.00 0.004 0.004 0.006 Surfaces Widths Up Thru 25mm Or Any 25mm Increment Of Wider Surfaces
Maximum Allowable Deviation D = Tolerance Factor . 25 (Mm)
25.01-40.00 0.004 0.004 0.004
40.01-50.00 0.004 0.004 0.004 Widths Over 25mm
Maximum Allowable Deviation D = Tolerance Factor . W (Mm)
Above 50.01 0.004 0.004 0.004

FLATNESS – EXTRUDED HOLLOW PROFILES

Minimum Thickness of Metal Forming the Surface (mm)
Width (mm)
(mm) 0-150 150.01-200 200.01-250
0.00-3.20 0.006 0.008 0.012
3.21-4.00 0.006 0.008 0.010
4.01-5.00 0.005 0.007 0.010
5.01-6.30 0.004 0.006 0.010
6.31-8.00 0.004 0.006 0.008
8.01-12.50 0.004 0.006 0.008 Surfaces Widths Up Thru 25mm Or
Any 25mm Increment Of Wider Surfaces
Maximum Allowable Deviation D = Tolerance Factor . 25 (mm)
12.51-20.00 0.004 0.004 0.006
20.01-25.00 0.004 0.004 0.006 Widths Over 25mm
Maximum Allowable Deviation D = Tolerance Factor . W (mm)
25.01-40.00 0.004 0.004 0.004

STRAIGHTNESS – EXTRUDED ROD, BAR AND PROFILES

Product
Specified Diameter (Rod), Specified Width (Bar) & Circumscribing Circle Diameter (Profiles)(mm) Specified Thickness  (Rectangles), Minimum Thickness (Profiles) (mm) Tolerance (mm)
Rod and Square. Hexagonal and Octagonal Bar All All 1 mm/m
Rectangular Bar 0.00 – 40.00 0.00 – 2.50 4 mm/m
> 2.50 1 mm/m
> 40.00 All 1 mm/m
Profiles 0.00 – 40.00 0.00 – 2.50 4 mm/m Allowable deviation from straight, D(max), in total length or in any 300 mm or longer chord segment of total length
> 2.50 1 mm/m

TWIST – EXTRUDED BAR AND PROFILES

Product
Specified Width (Bar), Circumscribing Circle Diameter (Profiles) (mm) Specified Thickness (Rectangles), Minimum Thickness (Profiles) (mm) Tolerance (Degree)
Bar 0.00 – 40.00 All 3 ͦ/m but not greater than 7 ͦ
40.01 – 80.00 All 1.5 ͦ/m but not greater than 5 ͦ
> 80.00 All 1 ͦ/m but not greater than 3 ͦ
Profiles 0.00 – 40.00 All 3 ͦ/m but not greater than 7 ͦ Allowable deviation from straight, y(max), in total length or in any 300 mm chord segment of the total length
 40.01 – 80.00 All 1.5 ͦ/m but not greater than 5 ͦ
> 80.00 All 1 ͦ/m but not greater than 3 ͦ

Source : The Aluminum Association ( International Alloy Designations and Chemical Composition Limits for
Wrought Aluminium and Wrought Aluminium Alloys, Jan 2015)