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" |