← Back to Bead BoardAluminum flat bar weight calculator
Aluminum flat bar is the everyday stock for brackets, straps, gussets, and trim. 6061-T6 is 0.0975 lb/in³ — roughly a third of mild steel. A 2×1/4 bar is 0.59 lb/ft. A 3×1/2 bar is 1.76 lb/ft. Enter width and thickness below.
Quick answer
Calculate 6061 aluminum flat bar weight by width, thickness, and length.
Common 6061 aluminum flat bar weights
Weight = width × thickness × length × 0.0975. Values match the calculator above. Mill tolerance on extruded bar is tight, usually within ±2%.
Questions welders ask about this one
How much does 2×1/4 aluminum flat bar weigh?
About 0.59 lb per foot in 6061. Math: 2 × 0.25 × 12 × 0.0975 = 0.59 lb/ft. The same bar in mild steel is 1.70 lb/ft.
How do I calculate aluminum flat bar weight for any size?
Width (in.) × thickness (in.) × length (in.) × 0.0975 lb/in³. Example: a 1.5 × 3/8 bar at 12 ft is 1.5 × 0.375 × 144 × 0.0975 = 7.9 lb. Or use the calculator above and skip the math.
Is aluminum flat bar the same weight in 6061 and 5052?
Almost. 6061-T6 is 0.0975 lb/in³ and 5052 is 0.0968 — under 1% apart. 5052 is the more formable, marine-grade alloy; 6061 is the structural one. For quoting they weigh the same.
Weight is only half of material cost. To turn these pounds into a number you can quote, run the weld cost calculator for wire, gas, and labor per inch, or the job pricing calculator to build the whole bid.
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