Tolerance Standards for Aluminum Extrusions

The specification for dimensional tolerances in aluminum profiles refers to the specific regulations defining the allowable range of dimensional deviations during manufacturing. These regulations help ensure product quality and reliability. MASTAR offers various aluminum extrusion profiles, and the dimensional tolerances of these profiles comply with EN755 and EN12020 standards.

Different alloys have different tolerance standards, with alloys grouped into Group 1 and Group 2.

Group 1	Group 2
1050, 1070, 1200, 1350, 3102, 3003, 3103 5005, 5005A, 5051A, 5251 6101A, 6101B, 6005, 6005A, 6106, 6008, 6010A, 6012, 6014, 6018, 6023, 6351, 6060, 6360, 6061, 6261, 6262, 6262A, 6063, 6063A, 6463, 6065, 6081, 6082, 6182	2007, 2011, 2011A, 2014, 2014A, 2017A, 2024, 2030 5019, 5049, 5052, 5154A, 5454, 5754, 5083, 5086 7003, 7005, 7108, 7108A, 7020, 7021, 7022, 7049A, 7075

Diameter tolerances for aluminum extruded round bars

Diameter	Tolerances -Group 1	Tolerances - Group 2
10 - 18mm	+/- 0.22mm	+/- 0.3mm
19 - 25mm	+/- 0.25mm	+/- 0.35mm
26 - 40mm	+/- 0.3mm	+/- 0.4mm
41 - 50mm	+/- 0.35mm	+/- 0.45mm
51 - 65mm	+/- 0.4mm	+/- 0.5mm
66 - 80mm	+/- 0.45mm	+/- 0.7mm
81 - 100mm	+/- 0.55mm	+/- 0.9mm
101 - 120mm	+/- 0.65mm	+/- 1mm
121 - 150mm	+/- 0.8mm	+/- 1.2mm
151 - 180mm	+/- 1mm	+/- 1.4mm
181 - 220mm	+/- 1.15mm	+/- 1.7mm
221 - 270mm	+/- 1.3mm	+/- 2mm
271 - 320mm	+/- 1.6mm	+/- 2.5mm

Aluminum rectangular bars - dimensional tolerances

Widths Across Flats	Tolerances -Group 1	Tolerances - Group 2
10 - 18mm	+/- 0.25mm	+/- 0.35mm
19 - 30mm	+/- 0.3mm	+/- 0.4mm
31 - 50mm	+/- 0.4mm	+/- 0.5mm
51 - 80mm	+/- 0.6mm	+/- 0.7mm
81 - 120mm	+/- 0.8mm	+/- 1mm
121 - 180mm	+/- 1mm	+/- 1.4mm
181 - 240mm	+/- 1.4mm	+/- 1.8mm
241 - 350mm	+/- 1.8mm	+/- 2.2mm
351 - 450mm	+/- 2.2mm	+/- 2.8mm
451 - 600mm	+/- 3mm	+/- 3.5mm

Aluminum square bars - dimensional tolerances

Widths Across Flats	Tolerances -Group 1	Tolerances - Group 2
10-18mm	+/- 0.22mm	+/- 0.30mm
19 - 25mm	+/- 0.25mm	+/- 0.35mm
26 - 40mm	+/- 0.30mm	+/- 0.40mm
41 - 50mm	+/- 0.35mm	+/- 0.45mm
51 - 65mm	+/- 0.40mm	+/- 0.50mm
66 - 80mm	+/- 0.45mm	+/- 0.70mm
81 - 100mm	+/- 0.55mm	+/- 0.90mm
101 - 120mm	+/- 0.65mm	+/- 1.00mm
121 - 150mm	+/- 0.80mm	+/- 1.20mm
151 - 180mm	+/- 1.00mm	+/- 1.40mm
181 - 220mm	+/- 1.15mm	+/- 1.70mm

Aluminum hexagonal bars - dimensional tolerances

Widths Across Flats	Tolerances -Group 1	Tolerances - Group 2
10-18mm	+/- 0.22mm	+/- 0.30mm
19 - 25mm	+/- 0.25mm	+/- 0.35mm
26 - 40mm	+/- 0.30mm	+/- 0.40mm
41 - 50mm	+/- 0.35mm	+/- 0.45mm
51 - 65mm	+/- 0.40mm	+/- 0.50mm
66 - 80mm	+/- 0.50mm	+/- 0.70mm
81 - 100mm	+/- 0.55mm	+/- 0.90mm
101 - 120mm	+/- 0.65mm	+/- 1.00mm
121 - 150mm	+/- 0.80mm	+/- 1.20mm
151 - 180mm	+/- 1.00mm	+/- 1.40mm
181 - 220mm	+/- 1.15mm	+/- 1.70mm

Rectangular bar- squareness tolerances

Widths Across Flats	Max Deviation from Square
2 - 10mm	0.10mm
11 - 100mm	0.01mm x Width Across Flats
101 - 180mm	1.00mm
181 - 240mm	1.50mm

Square bar- squareness tolerances

Width Across Flats	Max Deviation from Square
10 - 100mm	0.01mm x Width Across Flats
101 - 180mm	1.00mm
181 - 220mm	1.50mm

Square bars - MAX CORNER RADII

Width Across Flats	Tolerances - Group 1	Tolerances - Group 2
10-25mm	+/- 1.00mm	+/- 1.50mm
26 - 50mm	+/- 1.50mm	+/- 2.00mm
51 - 80mm	+/- 2.00mm	+/- 3.00mm
81 - 120mm	+/- 2.50mm	+/- 3.00mm
121 - 180mm	+/- 2.50mm	+/- 4.00mm
180 - 220mm	+/- 3.50mm	+/- 5.00mm

Rectangular bar - thickness tolerances - group 1

Width Across Flats	Tols: (Thick:2-6mm)	Tols: (Thick:6.1-10mm)	Tols: (Thick:10.1-18mm)	Tols:(Thick:19-30mm)	Tols: (Thick:31-50mm)	Tols: (Thick:51-80mm)	Tols: (Thick:81-120mm)	Tols: (Thick:121-180mm)	Tols: (Thick:181-240mm)
10 - 18mm	+/- 0.20mm	+/- 0.25mm	+/- 0.25mm	-	-	-	-	-	-
19 - 30mm	+/- 0.20mm	+/- 0.25mm	+/- 0.30mm	+/- 0.30mm	-	-	-	-	-
31 - 50mm	+/- 0.25mm	+/- 0.25mm	+/- 0.30mm	+/- 0.35mm	+/- 0.40mm	-	-	-	-
51 - 80mm	+/- 0.25mm	+/- 0.30mm	+/- 0.35mm	+/- 0.40mm	+/- 0.50mm	+/- 0.60mm	-	-	-
81 - 120mm	+/- 0.30mm	+/- 0.35mm	+/- 0.40mm	+/- 0.45mm	+/- 0.60mm	+/- 0.70mm	+/- 0.80mm	-	-
121 - 180mm	+/- 0.40mm	+/- 0.45mm	+/- 0.50mm	+/- 0.55mm	+/- 0.60mm	+/- 0.70mm	+/- 0.90mm	+/- 1.00mm	-
181 - 240mm	-	+/- 0.55mm	+/- 0.60mm	+/- 0.65mm	+/- 0.70mm	+/- 0.80mm	+/- 1.00mm	+/- 1.20mm	+/- 1.40mm
241 - 350mm	-	+/- 0.65mm	+/- 0.70mm	+/- 0.75mm	+/- 0.80mm	+/- 0.90mm	+/- 1.10mm	+/- 1.30mm	+/- 1.50mm
351 - 450mm	-	-	+/- 0.80mm	+/- 0.85mm	+/- 0.90mm	+/- 1.00mm	+/- 1.20mm	+/- 1.40mm	+/- 1.60mm
451 - 600mm	-	-	-	-	+/- 0.90mm	+/- 1.00mm	+/- 1.40mm	-	-

Rectangular Bar - Thickness Tolerances-Group 2

Widths Across Flats	Tols: (Thick:2-6mm)	Tols: (Thick:6.1-10mm)	Tols: (Thick:10.1-18mm)	Tols: (Thick:19-30mm)	Tols: (Thick:31-50mm)	Tols: (Thick:51-80mm)	Tols: (Thick:81-120mm)	Tols: (Thick:121-180mm)	Tols: (Thick:181-240mm)
10-18mm	+/- 0.25mm	+/- 0.30mm	+/- 0.35mm	-	-	-	-	-	-
19 - 30mm	+/- 0.25mm	+/- 0.30mm	+/- 0.40mm	+/- 0.40mm	-	-	-	-	-
31 - 50mm	+/- 0.30mm	+/- 0.30mm	+/- 0.40mm	+/- 0.50mm	+/- 0.50mm	-	-	-	-
51 - 80mm	+/- 0.30mm	+/- 0.35mm	+/- 0.45mm	+/- 0.60mm	+/- 0.70mm	+/- 0.70mm	-	-	-
81 - 120mm	+/- 0.35mm	+/- 0.40mm	+/- 0.50mm	+/- 0.60mm	+/- 0.70mm	+/- 0.80mm	+/- 1.00mm	-	-
121 - 180mm	+/- 0.45mm	+/- 0.50mm	+/- 0.55mm	+/- 0.70mm	+/- 0.80mm	+/- 1.00mm	+/- 1.10mm	+/- 1.40mm	-
181 - 240mm	-	+/- 0.60mm	+/- 0.65mm	+/- 0.70mm	+/- 0.90mm	+/- 1.10mm	+/- 1.30mm	+/- 1.60mm	+/- 1.80mm
241 - 350mm	-	+/- 0.70mm	+/- 0.75mm	+/- 0.80mm	+/- 0.90mm	+/- 1.20mm	+/- 1.40mm	+/- 1.70mm	+/- 1.90mm
351 - 450mm	-	-	+/- 0.90mm	+/- 1.00mm	+/- 1.10mm	+/- 1.40mm	+/- 1.80mm	+/- 2.10mm	+/- 2.30mm
451 - 600mm	-	-	-	-	+/- 1.20mm	+/- 1.40mm	+/- 1.80mm	-	-

Seamless & Porthole round tube - diameter tolerances

Diameter (OD or ID)	Max Deviation of Mean Diameter	Max Deviation at Any Point (Not Annealed or Heat Treated)	Max Deviation at Any Point (Heat Treated)	Max Deviation at Any Point (Annealed)
8-18mm	+/- 0.25mm	0.40mm	0.60mm	1.50mm
19 - 30mm	+/- 0.30mm	0.50mm	0.70mm	1.80mm
31 - 50mm	+/- 0.35mm	0.60mm	0.90mm	2.20mm
51 - 80mm	+/- 0.40mm	0.70mm	1.10mm	2.60mm
81 - 120mm	+/- 0.60mm	0.90mm	1.40mm	3.60mm
121 - 200mm	+/- 0.90mm	1.40mm	2.00mm	5.00mm
201 - 350mm	+/- 1.40mm	1.90mm	3.00mm	7.60mm
351 - 450mm	+/- 1.90mm	2.80mm	4.00mm	10.0mm

Seamless round tube - wall thickness tolerances

Wall Thickness	Tolerance Measured at Any Point
0.5 - 3.0mm	+/- 10%
3.0 - 5.0mm	+/- 9%
Over 5.0mm	+/- 8%

Porthole round tube - wall thickness tolerances

Wall Thickness	Tolerance Measured at Any Point
3.0mm	+/- 7%
3.0 to 5.0mm	+/- 6%
Over 5.0mm	+/- 5%

Tolerance - Width, Depth or Width A/F for seamless & porthole tube

Width, Depth or Width A/F	Ovality Tolerances (+/- mm)	Ovality Tolerances (+/- mm)	Ovality Tolerances (+/- mm)	Ovality Tolerances (+/- mm)	Ovality Tolerances (+/- mm)	Ovality Tolerances (+/- mm)	Ovality Tolerances (+/- mm)	Ovality Tolerances (+/- mm)
	Group 1 0-100	Group 1 101-200	Group 1 201-300	Group 1 301-350	Group 2 1-100	Group 2 101-200	Group 2 201-300	Group 2 301-350
Up to 10	0.25	0.30	0.35	0.40	0.40	0.50	0.55	0.60
11 to 25	0.30	0.40	0.50	0.60	0.50	0.70	0.80	0.90
26 to 50	0.50	0.60	0.80	0.90	0.80	0.90	1.00	1.20
51 to 100	0.70	0.90	1.10	1.30	1.00	1.20	1.30	1.60
101 to 150	-	1.10	1.30	1.50	-	1.50	1.70	1.80
151 to 200	-	1.30	1.50	1.80	-	1.90	2.20	2.40
201 to 300	-	-	1.70	2.10	-	-	2.50	2.80
301 to 350	-	-	-	2.80	-	-	-	3.50

Tolerances on wall thickness for seamless tube (other than round tube)

Wall Thickness (mm)	Tolerances (+/-mm) for Given Circumscribing Circle	Tolerances (+/-mm) for Given Circumscribing Circle	Tolerances (+/-mm) for Given Circumscribing Circle	Tolerances (+/-mm) for Given Circumscribing Circle	Tolerances (+/-mm) for Given Circumscribing Circle	Tolerances (+/-mm) for Given Circumscribing Circle
	Group 1 Up to 100	Group 1 101 to 300	Group 1 301 to 350	Group 2 Up to 100	Group 2 101 to 300	Group 2 301 to 350
0.5 to 1.5	0.25	0.35	-	0.35	0.50	-
1.51 to 3.0	0.30	0.50	0.75	0.45	0.65	0.90
3.1 to 6.0	0.50	0.75	1.00	0.60	0.90	1.20
6.1 to 10.0	0.75	1.00	1.20	1.00	1.30	1.50
11 to 15	1.00	1.20	1.50	1.30	1.70	1.90
16 to 20	1.50	1.90	2.00	1.90	2.20	2.50
21 to 30	1.90	2.20	2.50	2.20	2.70	3.10
31 to 40	-	2.50	2.70	-	-	-

Tolerances on wall thickness for porthole tube (other than round tube)

	Tolerances (+/- mm) for Given Circumscribing Circle	Tolerances (+/- mm) for Given Circumscribing Circle	Tolerances (+/- mm) for Given Circumscribing Circle	Tolerances (+/- mm) for Given Circumscribing Circle	Tolerances (+/- mm) for Given Circumscribing Circle	Tolerances (+/- mm) for Given Circumscribing Circle
	Group 1 Up to 100	Group 1 101 to 300	Group 1 300 to 350	Group 2 Up to 100	Group 2 101 to 300	Group 2 300 to 350
0.5 to 1.5	0.20	0.30	-	0.30	0.40	-
1.51 to 3.0	0.25	0.40	0.60	0.35	0.50	0.70
3.1 to 6.0	0.40	0.60	0.80	0.55	0.70	0.90
6.1 to 10.0	0.60	0.80	1.00	0.75	1.00	1.20
11 to 15	0.80	1.00	1.20	1.00	1.30	1.50
16 to 20	1.20	1.50	1.70	1.50	1.80	2.00
21 to 30	1.50	1.80	2.00	1.80	2.20	2.50
31 to 40	-	2.00	2.00	-	2.50	3.00

Angle tolerance

Alloy(s)	Method	Thickness	Thick Tol. (over(+)/under(-))	Leg Tols ( Leg Length: 0.250"-0.624")	Leg Tols ( Leg Length: 0.625"-1.249")	Leg Tols ( Leg Length: 1.250"-2.499")	Leg Tols ( Leg Length: 2.500"-3.999")	Leg Tols ( Leg Length: 4.000"-5.999")
6061-T6, 6063(-T5/52)	Extruded	up to 0.124"	+/- 0.006"	+/- 0.010"	+/- 0.012"	-	-	-
6061-T6, 6063(-T5/52)	Extruded	0.125" to 0.249"	+/- 0.007"	+/- 0.012"	+/- 0.014"	+/- 0.016"	-	-
6061-T6, 6063-T52	Extruded	0.250" to 0.499"	+/- 0.008"	+/- 0.014"	+/- 0.016"	+/- 0.018"	+/- 0.020"	-
6061-T6, 6063-T52	Extruded	0.500" to 0.749"	+/- 0.009"	+/- 0.016"	+/- 0.018"	+/- 0.020"	+/- 0.022"	-
6061-T6, 6063-T52	Extruded	0.750" to 0.999"	+/- 0.010"	+/- 0.018"	+/- 0.020"	+/- 0.022"	+/- 0.025"	+/- 0.030"
6061-T6, 6063-T52	Extruded	1.000" to 1.499”	+/- 0.012"	+/- 0.021"	+/- 0.023"	+/- 0.026"	+/- 0.030"	+/- 0.035"
6061-T6, 6063-T52	Extruded	1.500" to 1.999"	+/- 0.014"	+/- 0.024"	+/- 0.026"	+/- 0.031"	+/- 0.036"	+/- 0.042"
6061-T6, 6063-T52	Extruded	2.000" to 3.999"	+/- 0.024"	+/- 0.034"	+/- 0.038"	+/- 0.048"	+/- 0.057"	+/- 0.068"
6061-T6, 6063-T52	Extruded	4.000" to 5.999"	+/- 0.034"	+/- 0.044"	+/- 0.050"	+/- 0.064"	+/- 0.078"	+/- 0.094"
6061-T6, 6063-T52	Extruded	6.000" to 7.999"	+/- 0.044"	+/- 0.054"	+/- 0.062"	+/- 0.082"	+/- 0.099"	+/- 0.120"
6061-T6, 6063-T52	Extruded	8.000" to 9.999"	+/- 0.054"	+/- 0.064"	+/- 0.074"	+/- 0.100"	+/- 0.120"	+/- 0.145"

Architectural channel

Alloy(s)	Method	Thickness(inch)	Thick Tol. (over(+)/under(-))	Leg Tols ( Leg Length: 0.250"-0.624")	Leg Tols ( Leg Length: 0.625"-1.249")	Leg Tols ( Leg Length: 1.250"-2.499")	Leg Tols ( Leg Length: 2.500"-3.999")
6063-T52	Extruded	Up to 0.124"	+/- 0.006"	+/- 0.010"	+/- 0.012"	-	-
6063-T52	Extruded	0.125" to 0.249"	+/- 0.007"	+/- 0.012"	+/- 0.014"	+/- 0.016"	-
6063-T52	Extruded	0.250" to 0.499"	+/- 0.008"	+/- 0.016"	+/- 0.016"	+/- 0.018"	+/- 0.020"
6063-T52	Extruded	0.500" to 0.749"	+/- 0.009"	+/- 0.018"	+/- 0.018"	+/- 0.020"	+/- 0.022"