Equal H channel
Both slots are the same width, for joining two identical panels such as two 6 mm display boards or two 10 mm polycarbonate sheets.
Panel-joining extrusions
Aluminium H Channel & H-Bar Extrusions
An aluminium H channel is an extruded profile with two parallel slots back to back, so the edge of one panel slides into each side and the joint is held straight, flush and covered. Metline supplies H channels and H-bars in 6063, 6061 and 6082 alloys, in standard sizes or to your drawing, mill finished, anodised or powder coated, to customers worldwide.
- Common alloys
- 6063-T5, 6063-T6, 6061-T6
- Panel fits
- about 1.5 mm to 25 mm
- Lengths
- 3 m, 6 m or cut to size
- Standards
- ASTM B221 · EN 755 · EN 12020
What an aluminium H channel does
Seen end-on, the section looks like the letter H turned on its side: a central web (sometimes called the connector) with two flanges above and two below. Each pair of flanges forms a slot, and the slot width is matched to the thickness of the panel it will hold.
The profile solves a simple but recurring problem: how to join two flat sheets edge to edge so the seam stays straight, the cut edges are hidden, and the panels can move slightly with temperature without opening a gap. Shopfitters use it to butt-join display boards and slatwall, glaziers use it between polycarbonate or acrylic sheets, joiners use it to divide cabinet and wardrobe panels, and trailer and RV builders use it to join interior wall linings.
Aluminium is the usual material because it can be extruded into thin, accurate slots with sharp corners, it does not rust, it accepts anodising and powder coating, and it is light enough to fit by hand. Rigid PVC H sections are cheaper, but they creep under load, yellow in sunlight and cannot carry fixings; steel is stronger but needs coating and is far heavier.
Types of aluminium H channel and H-bar
Unequal (reducing) H
Different slot widths on each side, so a 12 mm board can meet a 6 mm sheet with both faces flush on one side.
Structural H-bar
Thicker flanges and web in 6061-T6 or 6082-T6, used where the joint also carries load, such as trailer wall joints or framed partitions.
Polycarbonate glazing H
Deep slots with room for expansion and, often, a snap-on cap or gasket groove, for multiwall polycarbonate roofing and greenhouse glazing.
Divider and slatwall H
Slim decorative profiles with a narrow visible face that separate panels in shopfitting, signage and wall cladding.
Angled H-bar
Slots set at an angle (for example 30°, 45° or 90°) to join panels at a corner or a faceted wall without a separate corner trim.
Which alloy and temper to specify
Most H channels are made from 6063 in T5 temper. It extrudes easily into thin flanges, holds tight slot tolerances and gives the most even anodised colour, which is what a visible trim needs. Specify 6063-T6 if the flanges must resist bending when panels are pushed in, and 6061-T6 or 6082-T6 when the joint is structural.
| Alloy and temper | Min. tensile Rm | Min. yield Rp0.2 | Min. elongation A | Character |
|---|---|---|---|---|
| 6060-T5 (EN AW-6060) | 160 MPa | 120 MPa | 6 % | Very easy to extrude, smooth surface, good anodising |
| 6063-T5 (ASTM B221, ≤ 12.7 mm) | 152 MPa / 22 ksi | 110 MPa / 16 ksi | 8 % | The standard trim and architectural alloy |
| 6063-T6 (ASTM B221) | 207 MPa / 30 ksi | 172 MPa / 25 ksi | 8 % | About a third stronger than T5 with the same finish quality |
| 6061-T6 (ASTM B221) | 260 MPa / 38 ksi | 240 MPa / 35 ksi | 8 – 10 % | Structural strength, machines well, slightly duller anodised colour |
| 6082-T6 (EN 755-2, ≤ 5 mm) | 290 MPa | 250 MPa | 8 % | European structural alternative to 6061 |
Values are specified minimums for thin open profiles; limits change with wall thickness band and are confirmed on the mill certificate. Typical 6063-T5 strength is about 185 MPa tensile and 145 MPa yield.
Physical properties (6063-T5)
- Density
- 2.69 – 2.70 g/cm³
- Modulus of elasticity
- about 69 GPa
- Thermal expansion
- about 23.4 µm/m·°C, roughly twice that of steel
- Thermal conductivity
- about 200 – 209 W/m·K
- Hardness
- about 60 HB (T5), 73 HB (T6)
H channel sizes and how to choose one
An H channel is sized by the panel it holds, not by its outside dimensions. Start with the actual measured panel thickness, then add a clearance: about 0.3 – 0.5 mm for a firm push fit on rigid boards, and more for plastics such as polycarbonate and acrylic, which expand several times more than aluminium.
| Panel thickness | Typical slot width | Typical use |
|---|---|---|
| 1.5 – 2 mm (1/16 in) | 2 – 2.5 mm | Thin aluminium sheet, ACP skins, laminate |
| 3 mm (1/8 in) | 3.2 – 3.5 mm | Signboards, acrylic, aluminium composite panel |
| 4 – 6 mm (1/4 in) | 4.5 – 6.5 mm | Hardboard, solid polycarbonate, display panels |
| 8 – 10 mm | 8.5 – 10.5 mm | Twinwall polycarbonate, MDF wall panels |
| 12 mm (1/2 in) | 12.5 – 13 mm | Plywood, cabinet carcass panels, slatwall |
| 16 – 19 mm (3/4 in) | 16.5 – 19.5 mm | Furniture board, partition panels |
| 25 mm (1 in) | 25.5 – 26 mm | Insulated or sandwich panels |
Standard supply
- Wall thickness
- about 1.0 – 3.0 mm for trims; thicker for structural H-bar
- Lengths
- 3 m and 6 m mill lengths; imperial 8 ft, 12 ft and 20 ft; cut-to-length pieces on request
- Length tolerance
- typically ±1 mm on cut lengths, tighter by agreement
- Custom sections
- New dies made to your drawing for special slot widths, faces or gasket grooves
Many standard H sections can be supplied from existing dies, which avoids tooling cost. Send the panel thickness and the face width you want and we will match the nearest available section.
Tolerances, straightness and inspection
Slot width is the dimension that matters most: too tight and panels will not go in, too loose and they rattle. Architectural H channels in 6060 and 6063 can be ordered to the precision tolerances of EN 12020-2, which are noticeably tighter than the general profile tolerances of EN 755-9 or the ANSI H35.2 tables referenced by ASTM B221.
What we check
- Cross-section
- Slot widths, flange lengths and wall thickness measured against the drawing
- Straightness and twist
- Checked over the full length; stretched after extrusion to remove bow
- Surface
- Visual inspection of decorative faces; anodic or coating thickness measured on finished parts
- Certification
- Mill test certificate to EN 10204 3.1 with chemistry and mechanical results
Finishes for aluminium H channel
Mill finish
As extruded and cleaned. The economical choice when the channel will be hidden, painted on site or used in a trailer interior.
Anodised
Clear (silver), satin, bronze, black, gold and champagne. Specify film thickness: about 10 – 15 µm for interiors and 20 – 25 µm for exterior use.
Powder coated
Any RAL or custom colour, matt to gloss. Exterior work is usually specified to QUALICOAT, with about 60 µm minimum coating thickness.
Brushed or polished
A mechanical finish before anodising gives a satin-brushed or bright look for furniture and retail fittings.
Wood-grain
Sublimation transfer over a powder base, for timber-look dividers in furniture and interiors.
Film-protected
A peelable protective tape on visible faces keeps the finish clean through cutting, transport and installation.
Cutting, fixing and installation tips
- Cutting: use a carbide-tipped, non-ferrous saw blade with a negative or low hook angle and light lubrication; deburr slot edges so they do not score panel faces.
- Fixing: most H channels rely on the panels for support. Where the channel must be fixed, drill and countersink through the web and use stainless or coated screws.
- Expansion: leave a gap of a few millimetres at the bottom of each slot for plastic panels; a 2 m polycarbonate sheet can grow several millimetres between winter and summer.
- Adhesives: MS-polymer or structural silicone holds panels permanently; clean the slot with solvent first, as mill-finish oxide and extrusion lubricant reduce adhesion.
- Dissimilar metals: isolate the channel from copper or bare steel in damp areas to avoid galvanic corrosion.
- Bending: T5 and T6 sections can be bent to large radii; order in a softer temper or ask for factory bending for tight curves.
Where aluminium H channel is used
- Retail and exhibition: joining slatwall, display boards and graphic panels into long walls
- Glazing and roofing: joining polycarbonate and acrylic sheets in canopies, greenhouses and skylights
- Furniture and joinery: dividing wardrobe, cabinet and shelving panels with a visible metal line
- Interior partitions: joining wall panels and glass in offices, clean rooms and healthcare interiors
- Transport: trailer doors, RV and caravan wall linings and cargo-van panelling
- Signage: joining sign faces and aluminium composite panels on frames
- Cladding: joints between ACP or solid aluminium cladding sheets on light frames
H channel compared with other joining profiles
| Profile | How it holds panels | Best for |
|---|---|---|
| H channel | Two opposed slots, panels pushed in from each side | Straight edge-to-edge joints |
| J channel | One slot with a longer back leg for fixing | Panel edges, ends of runs, mirror framing |
| U channel | One open slot | Edge capping, sliding tracks |
| F channel | Slot plus a fixing flange | Soffits and panel edges against a wall |
| I-beam | Not a panel holder; a load-carrying beam | Structural spans |
A useful rule: use an H channel wherever two panels meet in the middle of a run, a J or F channel where a run ends, and a corner or angle trim where it turns.
How to order aluminium H channel
- SpecifyPanel thickness on each side, visible face width, alloy and temper (e.g. 6063-T5), finish and colour, lengths and quantity, or a drawing for a custom section.
- QuoteWe confirm the die (existing or new), alloy, temper, finish, packing and delivery terms (EXW, FOB, CIF or DAP) for your destination.
- SampleFor new or appearance-critical sections, a short length or finish sample can be supplied for approval before the production run.
- ProcessProfiles are extruded or drawn from an existing die, aged, finished, cut to length and inspected for slot width and surface.
- DocumentEach delivery carries a mill test certificate to EN 10204 3.1 with cast analysis and mechanical results; coating thickness reports and third-party inspection on request.
- ShipLengths are film-protected, bundled with spacers and packed in cartons, crates or on pallets for sea, air or road freight to your port or door.
References and standards
- ASTM B221 – Standard Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes
- EN 755-2 – Aluminium and aluminium alloys: extruded rod/bar, tube and profiles, mechanical properties
- EN 12020-2 – Extruded precision profiles in alloys EN AW-6060 and EN AW-6063: tolerances on dimensions and form
- The Aluminum Association – International Alloy Designations and Chemical Composition Limits (Teal Sheets)
- QUALICOAT – Specifications for a quality label for liquid and powder organic coatings on aluminium for architectural applications
Aluminium (aluminum) H channel: frequently asked questions
How do I choose the right H channel size?
Measure the real thickness of the panel, not its nominal size, and choose a slot about 0.3 – 0.5 mm wider for rigid boards. For polycarbonate and acrylic allow extra depth at the bottom of the slot for thermal expansion.
Can one H channel join panels of different thickness?
Yes. An unequal or reducing H channel has a different slot width on each side, so, for example, a 12 mm board can join a 6 mm sheet. If no standard section suits, a custom die can be made.
Is 6063 or 6061 better for H channel?
6063-T5 is the normal choice for trims because it extrudes thin flanges accurately and anodises evenly. Choose 6061-T6 or 6082-T6 when the joint carries load, such as on trailer walls or framed partitions.
Can aluminium H channel be used outdoors?
Yes. Aluminium does not rust, and an anodised film of 20 – 25 µm or an exterior-grade powder coating gives long service outdoors, including for polycarbonate roofing and cladding joints.
What is the difference between an H channel and an H-beam?
An H channel is a light trim that holds panel edges. An aluminium H-beam or wide-flange beam is a structural member designed to carry bending loads, closer to an I-beam in purpose.
Do you supply H channel cut to length and drilled?
Yes. Metline can supply cut lengths, drilled or countersunk fixing holes, mitred ends and protective film, with mill certificates, packed for export worldwide.
Need H channel for your panels?
Send the panel thickness, finish, lengths and quantity, and we will match a section and quote a delivered price.
