An aluminium T bar is an extruded section shaped like a capital T: a flat flange with a single stem (web) at its centre. It is used to stiffen panels, join or support sheets and glazing, edge floors and build light frames, and it is extruded mainly in 6063 for architectural trim and 6061 or 6082 for structural duty. This guide gives standard sizes with calculated weights and section properties, explains rounded- and square-inside tees, and shows how to select alloy, temper and finish.
A T bar (tee bar, T section or T profile) has two elements: the flange, the horizontal top of the T, and the stem or web, which projects at 90° from its centre. It is an open, solid profile, so it is extruded on a flat die and is economical to tool, and its single plane of symmetry gives it useful stiffness in one direction while the flange provides a flat surface for fixing.
Sizes are given as flange width × overall height × thickness, for example 40 × 40 × 3 mm or 2 × 2 × 1/4 in. When the flange and stem have different thicknesses, both are stated (tf and tw). Make sure your drawing says whether the height is overall (top of flange to tip of stem) or stem only, because both conventions are used in catalogues.
Aluminium T bars do the same jobs as rolled steel tees but weigh about a third as much, never rust and can be anodised or powder coated. Small tees are mostly decorative and joining sections; larger ones act as stiffeners, purlins, floor bearers and lightweight beams. Because the centroid sits close to the flange, a tee is strong when the stem is in compression (stem down on a simply supported span with the flange on top) and weaker when the stem tip is in compression, which matters for cantilevers and continuous spans.
Has a fillet where the stem meets the flange and often rounded toes. The fillet reduces stress concentration and improves fatigue and buckling behaviour; it is the normal form for 6061 and 6082 load-bearing tees and for ASTM B308 standard structural profiles.
Sharp inside corner and crisp edges for a neat appearance. Common in 6063 and 6060 for trims, dividers, glazing bars and decorative frames, and easier to fit tight against panels.
Flange wider than the height (e.g. 50 × 25 mm) for cover strips and joint covers, or a tall stem (e.g. 50 × 100 mm) for stiffeners and bearers.
Custom tees with a thickened stem tip or lips on the flange, used as ship stiffeners, rails and snap-fit profiles.
Sections from about 12 mm with walls near 1.5 mm for trim, model making, electronics and interior details.
Thick sections, 8 mm and above, for floors, platforms, ladders and light beams in transport and industry.
All of these are produced the same way: a homogenised 6xxx billet is preheated, pushed through a flat steel die with a T-shaped aperture, quenched at the press exit (by air for 6063, by water mist or spray for thicker 6061 and 6082), stretched about 1 – 3 % to straighten it and relieve stress, cut to length and artificially aged to T5 or T6. Because the die is a simple solid die, tees in standard sizes are widely tooled and a new die for a custom tee is relatively inexpensive compared with a hollow profile. Larger tees, or tees with very thin stems relative to the flange, need larger presses and slower speeds so that the stem fills completely and stays straight.
Tees are almost always extruded in 6xxx alloys. Values are typical; the specified minimums in ASTM B221 and EN 755-2 depend on thickness and are what you design to and what appear on the mill certificate.
| Alloy & temper | Typical tensile | Typical yield | Weldability | Best use |
|---|---|---|---|---|
| 6063-T5 | 185 MPa / 27 ksi | 145 MPa / 21 ksi | Very good | Trims, dividers, glazing bars, decorative frames |
| 6063-T6 | 240 MPa / 35 ksi | 215 MPa / 31 ksi | Very good | Architectural tees that carry moderate loads |
| 6060-T66 | 215 MPa | 160 MPa | Very good | European architectural and interior systems |
| 6061-T6 / T6511 | 310 MPa / 45 ksi | 276 MPa / 40 ksi | Good | Structural tees, machinery, marine and transport |
| 6082-T6 | 310 – 340 MPa | 260 – 300 MPa | Good | European structural and transport tees |
| 6005A-T6 | 270 – 285 MPa | 225 – 240 MPa | Good | Rail, vehicle and solar structures |
Marine tees for ship stiffeners are also made in 5083 and 5086 (H111/H112), which keep their strength after welding and resist seawater, and aerospace tees in 2024 and 7075 are supplied to AMS-QQ-A-200 or AMS specifications where drawings require them. These grades extrude more slowly and are less available in small sizes.
| Property | 6063-T6 | 6061-T6 | 7075-T6 |
|---|---|---|---|
| Strength | Moderate | High | Very high |
| Weldability | Excellent | Good | Not recommended for fusion welding |
| Corrosion resistance | Excellent | Very good | Fair; needs protection |
| Surface and anodising | Best | Good | Good (hard anodise for wear) |
| Machinability | Fair (softer) | Very good | Excellent |
Values are calculated for an equal-thickness tee with a sharp inside corner at 2.70 g/cm³. Rounded-inside tees are a few percent heavier because of the fillet. The centroid is measured from the outer face of the flange; Ix is about the axis parallel to the flange (stem bending) and Iy about the stem axis.
| Flange × height × t (mm) | Area (mm²) | Weight (kg/m) | Centroid from flange (mm) | Iₓ (cm⁴) | Iᵧ (cm⁴) |
|---|---|---|---|---|---|
| 15 × 15 × 1.5 | 43 | 0.115 | 4.3 | 0.09 | 0.04 |
| 20 × 20 × 2 | 76 | 0.205 | 5.7 | 0.29 | 0.13 |
| 25 × 25 × 2 | 96 | 0.259 | 7.0 | 0.58 | 0.26 |
| 25 × 25 × 3 | 141 | 0.381 | 7.4 | 0.82 | 0.40 |
| 30 × 30 × 2 | 116 | 0.313 | 8.2 | 1.02 | 0.45 |
| 30 × 30 × 3 | 171 | 0.462 | 8.6 | 1.46 | 0.68 |
| 35 × 35 × 3 | 201 | 0.543 | 9.9 | 2.36 | 1.08 |
| 40 × 20 × 2 | 116 | 0.313 | 4.1 | 0.35 | 1.07 |
| 40 × 25 × 3 | 186 | 0.502 | 5.9 | 0.94 | 1.60 |
| 40 × 40 × 3 | 231 | 0.624 | 11.1 | 3.58 | 1.61 |
| 40 × 40 × 4 | 304 | 0.821 | 11.5 | 4.61 | 2.15 |
| 40 × 40 × 5 | 375 | 1.012 | 11.8 | 5.56 | 2.70 |
| 50 × 30 × 4 | 304 | 0.821 | 7.1 | 2.15 | 4.18 |
| 50 × 50 × 3 | 291 | 0.786 | 13.6 | 7.15 | 3.14 |
| 50 × 50 × 4 | 384 | 1.037 | 14.0 | 9.26 | 4.19 |
| 50 × 50 × 5 | 475 | 1.282 | 14.3 | 11.25 | 5.26 |
| 50 × 50 × 6 | 564 | 1.523 | 14.7 | 13.13 | 6.33 |
| 60 × 40 × 4 | 384 | 1.037 | 9.5 | 5.19 | 7.22 |
| 60 × 60 × 3 | 351 | 0.948 | 16.1 | 12.54 | 5.41 |
| 60 × 60 × 6 | 684 | 1.847 | 17.2 | 23.33 | 10.90 |
| 80 × 50 × 5 | 625 | 1.688 | 11.5 | 12.88 | 21.38 |
| 80 × 80 × 4 | 624 | 1.685 | 21.5 | 39.62 | 17.11 |
| 80 × 80 × 6 | 924 | 2.495 | 22.2 | 57.31 | 25.73 |
| 100 × 50 × 2 | 296 | 0.799 | 9.1 | 5.90 | 16.67 |
| 100 × 60 × 5 | 775 | 2.093 | 13.1 | 23.00 | 41.72 |
| 100 × 100 × 6 | 1164 | 3.143 | 27.2 | 114.39 | 50.17 |
| 100 × 100 × 10 | 1900 | 5.130 | 28.7 | 180.00 | 84.08 |
| 120 × 120 × 8 | 1856 | 5.011 | 33.0 | 261.02 | 115.68 |
Inch tees are ordered as flange × height × thickness in fractions of an inch. Weights below are calculated for sharp inside corners.
| Size (in) | Metric equivalent (mm) | Weight (kg/m) | Weight (lb/ft) | Iₓ (cm⁴) |
|---|---|---|---|---|
| 1/2 × 1/2 × 1/16 | 12.7 × 12.7 × 1.59 | 0.102 | 0.069 | 0.06 |
| 3/4 × 3/4 × 1/8 | 19.05 × 19.05 × 3.18 | 0.300 | 0.201 | 0.36 |
| 1 × 1 × 1/8 | 25.4 × 25.4 × 3.18 | 0.409 | 0.275 | 0.91 |
| 1-1/4 × 1-1/4 × 1/8 | 31.75 × 31.75 × 3.18 | 0.518 | 0.348 | 1.83 |
| 1-1/2 × 1-1/2 × 1/8 | 38.1 × 38.1 × 3.18 | 0.627 | 0.421 | 3.24 |
| 1-1/2 × 1-1/2 × 1/4 | 38.1 × 38.1 × 6.35 | 1.198 | 0.805 | 5.77 |
| 2 × 1 × 1/8 | 50.8 × 25.4 × 3.18 | 0.627 | 0.421 | 1.10 |
| 2 × 2 × 1/8 | 50.8 × 50.8 × 3.18 | 0.845 | 0.568 | 7.92 |
| 2 × 2 × 1/4 | 50.8 × 50.8 × 6.35 | 1.633 | 1.097 | 14.47 |
| 2-1/2 × 2-1/2 × 1/4 | 63.5 × 63.5 × 6.35 | 2.069 | 1.390 | 29.27 |
| 3 × 3 × 1/4 | 76.2 × 76.2 × 6.35 | 2.504 | 1.683 | 51.79 |
| 3 × 3 × 3/8 | 76.2 × 76.2 × 9.53 | 3.676 | 2.470 | 73.28 |
| 4 × 3 × 1/4 | 101.6 × 76.2 × 6.35 | 2.940 | 1.975 | 56.41 |
| 4 × 4 × 1/4 | 101.6 × 101.6 × 6.35 | 3.375 | 2.268 | 126.51 |
| 4 × 4 × 3/8 | 101.6 × 101.6 × 9.53 | 4.983 | 3.349 | 181.50 |
Standard lengths are 3 m, 5.8 m or 6 m in metric markets and 12 ft or 20 ft in inch markets. Exact cut lengths, mitres and drilled pieces are supplied on request.
A tee is not a symmetrical section, so its behaviour depends on which way it is loaded. Keep these points in mind when using a T bar as a structural member:
Where a tee is acting as a stiffener on a plate, the plate works with the flange as a combined section, so a modest tee can stiffen a large panel substantially. Ship and vehicle structures use this principle with tees welded or riveted to 5xxx or 6xxx plate.
As extruded; for hidden or later-painted parts.
Clear, black, bronze, champagne or gold, typically 10 – 25 µm; hard anodising for wear surfaces. 6063 gives the most uniform colour.
Any RAL colour for frames, furniture and architectural trim.
A thin, even lacquer film often applied over anodising for building profiles.
Decorative or matte surfaces for visible interior work and equipment.
Cutting to length and angle, drilling, punching, milling slots, tapping and CNC machining to drawing; marking for traceability.
Tees bend more easily about the axis that puts the flange on the outside of the bend. Tight bends are best made in T4 or O temper and then aged; T6 tees need large radii and trial bends.
T bars are supplied to the dimensional tolerances of the ordering standard unless the drawing sets tighter limits. For extruded profiles these are ANSI H35.2 (called up by ASTM B221) or EN 755-9. Tolerances depend on the size of the circumscribing circle, the alloy group and whether a dimension is across metal (thickness) or across a space. Angularity between flange and stem, flatness of the flange, straightness and twist are each specified separately.
Ordering "50 × 50" without stating whether 50 mm is overall height or stem length can give a tee that is a full flange thickness too short or too tall.
Square-inside architectural tees will not sit over a radius on a mating part, and rounded-inside tees leave a gap against flat panels. Specify the corner.
6063-T5 has roughly half the yield strength of 6061-T6. For bearers, stiffeners and brackets, specify 6061, 6082 or 6005A.
A tee designed with the stem in tension can fail early if installed upside down. Mark orientation on drawings for structural tees.
A 1 in tee is 25.4 mm, not 25 mm. Panels and glazing designed around one will not fit the other.
Powder coating adds roughly 60 – 120 µm per face, which matters when tees slot into tight panel grooves.
| Sector | Typical alloys | Examples |
|---|---|---|
| Building and interiors | 6063, 6060, 6061 | Glazing bars, ceiling grid members, panel joint covers, tile and floor dividers, thresholds and handrail brackets (profiles supplied to fabricators) |
| Industrial equipment | 6061, 6082, 6005A | Machine frames, conveyor supports, equipment brackets, guide rails |
| Rail and road transport | 6082, 6061, 6005A | Floor bearers, seat rails, body framing, trailer and truck body stiffeners |
| Marine | 5083, 5086, 6061 | Hull and deck stiffeners, hatch frames, equipment supports |
| Aerospace and defence | 2024, 7075, 6061 | Brackets, seat track and floor support members, ground equipment |
| Furniture and display | 6063 | Table and shelf frames, trims, exhibition and retail fixtures, lighting frames |
| Aluminium T bar | Steel T bar | |
|---|---|---|
| Weight | About one third of steel for the same size | Heavier, raising handling and freight cost |
| Corrosion | Natural oxide; anodise or coat for appearance | Needs paint or galvanising |
| Fabrication | Fast cutting, drilling and machining | Slower, harder on tools |
| Stiffness | Modulus about 69 GPa | Modulus about 200 GPa |
| Strength (common grade) | 6061-T6 typical yield 276 MPa | Structural steel yield about 235 – 355 MPa |
An aluminium tee replacing a steel tee of the same size will deflect roughly three times as much, so structural substitutions normally move up one or two sizes. The weight saving, no painting and easier site handling usually outweigh that.
As flange width × height × thickness. Most catalogues give the overall height from the top of the flange to the tip of the stem; if flange and stem thicknesses differ, both are stated. Confirm the convention on the drawing.
6061, 6063 and 6082 tees weld well by TIG or MIG with ER4043 or ER5356 filler, but the heat-affected zone loses part of its T6 strength. 5083 and 5086 marine tees keep more strength after welding. 7075 and 2024 tees should be bolted or riveted.
5083 or 5086 for welded stiffeners in seawater, and 6061-T6 or 6082-T6 for anodised or painted fittings above the waterline.
6061-T6 is about 30 % stronger and machines better, so it suits structural tees. 6063 has a smoother surface and anodises more evenly, so it suits trims, glazing bars and decorative frames.
Yes, with care. Bend with the flange on the outside where possible, use generous radii, and form tight bends in T4 or O temper before ageing.
About 0.62 kg/m for a sharp-inside-corner tee, slightly more with a root fillet.
Yes. Metline supplies standard tees and custom T profiles extruded to your drawing, with cutting, drilling and finishing on request and mill certificates for every lot.
Send sizes, alloy, temper, finish and quantities. Our team will confirm tooling and availability and send a delivered price anywhere in the world.
