Step-by-Step Guide to Working with Aluminum T-Section Extrusions


In the realm of construction and engineering, aluminum T-section extrusions reign supreme as versatile and durable building blocks. Their unique T-shaped profile unlocks a myriad of possibilities for creating robust and lightweight structures. This comprehensive guide will empower you with the knowledge and techniques to harness the incredible potential of aluminum T-section extrusions.

Step 1: Selecting the Right Extrusion

Determining the appropriate T-section extrusion depends on the specific application. Consider factors such as:

Thickness: Ranging from thin (0.063″) to thick (0.250″), choose the thickness that provides the necessary strength and rigidity.

Alloy: Select an alloy that balances strength, corrosion resistance, and workability. Common alloys include 6061-T6 and 6063-T5.

Length: Determine the desired length for your project and order custom-cut extrusions if necessary.

Step 2: Cutting and Shaping

Cutting: Aluminum T-sections can be easily cut using a miter saw, power shears, or hand tools like a hacksaw. Measure carefully and secure the extrusion before cutting.

Shaping: T-sections can be bent or rolled to create curves or rounded corners. Use a bending brake or roller to achieve precise shaping.

Step 3: Joining Techniques

Mechanical: Fasten extrusions using bolts, nuts, and washers. Rivets and threaded inserts offer additional strength.

Welding: TIG welding is an effective way to join aluminum T-sections. Ensure proper preparation and techniques for strong welds.

Adhesives: Structural adhesives can provide a strong and lightweight bond between extrusions.

Step 4: Finishing

Anodizing: Anodizing creates a protective oxide layer on the surface, enhancing corrosion resistance and aesthetics.

Painting: For a wide range of colors and finishes, consider painting the extrusions with high-quality enamel or powder coating.

Benefits of Aluminum T-Section Extrusions

Lightweight and Durable: Aluminum offers exceptional strength-to-weight ratio, making T-sections ideal for weight-sensitive applications.

Versatile: The T-shaped profile allows for easy joining and mounting, accommodating complex designs.

Corrosion Resistant: Aluminum naturally resists corrosion, reducing maintenance costs and extending the lifespan of structures.

Aesthetically Pleasing: T-sections add visual appeal to various projects, from building facades to industrial machinery.


Working with aluminum T-section extrusions is a rewarding experience that unlocks the potential for innovative and durable designs. By following these steps and understanding the benefits of T-sections, you can harness their versatility and create structures that stand the test of time.