Aluminum Extrusions Strength: How Much Can It Hold?

Introduction

Engineers, designers, and buyers often ask: how much weight can aluminum extrusion hold? or how strong is aluminum extrusion? The answer depends on factors like alloy type, temper, profile design, and application.

In this guide, we’ll break down the strength of aluminum extrusions, compare common alloys, and explore real-world load-bearing capacities so you can make informed sourcing decisions.

How Strong Is Aluminum Extrusion?

Aluminum extrusions are known for their high strength-to-weight ratio. While aluminum is about one-third the weight of steel, certain extruded alloys deliver excellent tensile and yield strength.

Key Strength Properties:

• Tensile Strength – the maximum stress before breaking.
• Yield Strength – the point where permanent deformation begins.
• Design Factors – geometry, wall thickness, and heat treatment all affect real-world performance.

In structural applications, aluminum extrusions are often engineered to rival or even replace steel, particularly where weight reduction is critical.

How Much Weight Can Aluminum Extrusion Hold?

The weight capacity of aluminum extrusion depends on three main factors:

1. Alloy and Temper
   • Different alloys deliver different strength levels.
2. Cross-Sectional Design
   • Thicker walls and reinforced shapes hold more load.
3. Load Conditions
   • Point load vs. distributed load, static vs. dynamic stresses, and support spacing all matter.

For example:

• 6061-T6 aluminum extrusion can reach tensile strengths of ~45,000 psi.
• 6063-T5 aluminum extrusion is typically around ~21,000 psi but has excellent corrosion resistance and surface finish.

In practical terms, a standard 1″ x 1″ 80/20 aluminum extrusion can support hundreds of pounds when properly braced, while larger structural profiles can handle loads in the thousands of pounds range.

How Much Weight Different Aluminum Extruded Alloys Hold

Here’s a comparison of common extrusion alloys and their approximate strength ranges (values vary by design and temper):

Alloy & Temper	Tensile Strength (psi)	Yield Strength (psi)	Typical Applications
6061-T6	~45,000	~40,000	Aerospace, automotive, structural framing
6063-T5	~21,000	~16,000	Architectural framing, windows, consumer products
7075-T6	~83,000	~73,000	Aerospace, defense, high-stress components
2024-T3	~68,000	~47,000	Aircraft structures, transportation

Takeaway: The stronger the alloy, the more weight the extrusion can hold, but corrosion resistance, machinability, and cost must also be considered.

Real-World Applications of Extrusion Strength

• Architectural & Construction – curtain wall framing, beams, and supports hold large static loads.
• Transportation – extruded frames reduce weight while maintaining safety in vehicles and trains.
• Aerospace – high-strength alloys like 7075 withstand extreme stresses with minimal weight.
• Industrial Machinery – modular extrusion systems handle dynamic loads in automation and assembly lines.

Conclusion

So, how much weight can aluminum extrusion hold? The answer: it depends on the alloy, design, and application—but extruded aluminum is strong enough for everything from consumer products to aerospace structures.

And how strong is aluminum extrusion? With alloys like 6061 and 7075, extruded profiles can rival steel strength while remaining lightweight, corrosion resistant, and versatile.

For buyers and engineers, choosing the right extrusion strength means matching alloy properties to application needs—balancing strength, weight, and cost.