Aluminum Weight Calculator
Estimate the weight of aluminum stock — sheet/plate, bar, tube, and more. Pick a profile, enter the dimensions in inches (length in feet), choose an alloy (or type a custom density), and get total weight in pounds and kilograms, weight per piece, weight per foot, and cost — with a weight-by-alloy comparison and a downloadable PDF.
| Alloy | Density | Per foot | Total weight |
|---|---|---|---|
| Enter a size to compare alloys | |||
| Pieces | Total weight | Kilograms | Cost |
|---|---|---|---|
| Enter a size to compare | |||
Aluminum Weight Calculator — Complete Guide for 2026
Aluminum is sold, shipped, and often priced by the pound, but it is specified by size — a 1/8 in sheet, a 1 in round bar, a 1.5 in tube with a 0.125 in wall. Whether you are quoting a fabrication job, planning a trailer or boat build, checking a shipping weight, or just deciding whether one person can carry a sheet, you need to turn those dimensions into a weight.
Our free Aluminum Weight Calculator covers the six most common stock profiles — sheet/plate, round bar, round tube, square bar, flat bar, and hex bar — with dimensions in inches, feet, or millimeters. Choose an alloy (6061, 6063, 1100, 3003, 5052, 5083, 2024, 7075, or pure aluminum) or a custom density, and get total weight in pounds and kilograms, weight per piece, weight per foot, and cross-section area, plus an optional cost. A weight-by-alloy table, a table by number of pieces, a chart, and a downloadable PDF round it out.
How to Use the Aluminum Weight Calculator in 4 Steps
A complete estimate takes under a minute. Pick a profile, enter its size as specified, choose an alloy, and download a PDF for a quote, shipping form, or cut list.
Choose a Profile & Enter Its Size
Select Sheet / plate (width × thickness), Round bar (diameter), Round tube (outer diameter × wall), Square bar (side), Flat bar (width × thickness), or Hex bar (across flats). The fields relabel for each profile. Enter the length and the number of pieces, with inches, feet, or mm for each dimension.
Pick an Alloy
Choose 6061 (the default), 6063, 1100, 3003, 5052, 5083, 2024, 7075, or pure aluminum. The density fills in automatically in lb/ft³, from 166.1 for 5083 to 175.4 for 7075. For anything else, type a density from a mill spec sheet; the selector switches to Custom.
Add a Price (Optional)
Enter a price and choose per pound (the default, and how aluminum stock is usually priced) or per ton (2,000 lb, common for scrap and bulk). Leave the price at 0 to skip the cost estimate.
Review & Download the Report
The hero result shows total weight in pounds. Cards add weight per piece, weight per foot, and kilograms; the summary adds the cross-section area and cost. The weight-by-alloy table and chart compare seven alloys at your size, and the pieces table scales from 1 to 25 pieces. Click Download report for a branded PDF.
Aluminum Density and the Six Profile Formulas
Aluminum’s light weight is the reason it is used in trailers, boats, aircraft, railings, and window frames. At about 2.70 g/cm³, it weighs roughly one third as much as steel (about 490 lb/ft³) for the same size. In US units, 6061 is about 168.6 lb per cubic foot, which works out to 0.0976 lb per cubic inch — the number most shop rules of thumb are built on.
Because bar, tube, and sheet are long, uniform pieces, the easiest way to find weight is from the cross-section: multiply the area of the end face by the length and the density. The calculator converts every dimension to feet (inches ÷ 12, mm ÷ 304.8) and uses these cross-section formulas:
- Sheet / plate and flat bar: width × thickness.
- Round bar: π ÷ 4 × diameter².
- Round tube: π ÷ 4 × (outer diameter² − inner diameter²), where inner diameter = outer diameter − 2 × wall. Only the wall carries weight.
- Square bar: side².
- Hex bar: √3 ÷ 2 × (across flats)², or about 0.866 × AF². Hex is measured across the flat faces, not the corners.
Why alloys weigh slightly different amounts
Aluminum alloys are mostly aluminum with small additions of other elements. Alloys that add heavier elements like copper (2024) or zinc (7075) are a little denser — up to about 2.81 g/cm³ — while magnesium alloys (5052, 5083) are a little lighter, around 2.66–2.68 g/cm³. Across the calculator’s alloys, the spread from lightest to heaviest is only about 5.6%, so the alloy matters less than getting the dimensions right. Temper (such as T6 or H32) changes strength, not density.
What the Aluminum Weight Calculator Calculates
Every output comes from the same profile, dimensions, piece count, and density, so total weight, per-piece and per-foot weights, kilograms, and cost always agree with each other and with the tables and chart.
Total Weight in Pounds (Hero Result)
Weight per piece × number of pieces, shown to one decimal. At the default inputs — a 6061 sheet strip 12 in wide, 0.125 in thick, and 8 ft long — the result is 14.0 lb (14.05 lb before rounding). The hero line also summarizes the alloy, profile, and dimensions.
Weight per Foot
Cross-section × density — the standard way bar, tube, and extrusions are listed in supplier catalogs, and the number to use when you cut stock to different lengths. Multiply by any length in feet for that piece’s weight. Default: 1.76 lb/ft.
Weight per Piece & Cross-Section
The weight of a single piece — what one person has to lift — and the cross-section area in square inches, so you can check the geometry against a catalog. Defaults: 14.0 lb per piece and 1.5 sq in cross-section.
Kilograms & Estimated Cost
Kilograms (lb × 0.45359237) for international orders and metric specs — default 6.4 kg. Cost = total pounds × price per pound, or pounds ÷ 2,000 × price per ton; for example, 14.05 lb at $5 per pound is about $70. Cost shows a dash when the price is 0.
Alloy & Pieces Tables + Chart
The weight-by-alloy table shows density, weight per foot, and total weight for 6061, 6063, 1100, 3003, 5052, 2024, and 7075 at your size. The pieces table shows total weight, kilograms, and cost for 1, 2, 5, 10, and 25 pieces, and the bar chart compares weight by alloy.
PDF Report
The PDF includes a branded header, the total weight, a size-and-weight table, the weight-by-alloy table, the pieces table, and an estimate note — ready to attach to a quote, purchase order, shipping form, or cut list.
Aluminum Weight Chart — Common Bar & Tube Sizes (6061)
Weights below use 6061 at 168.6 lb/ft³ and nominal sizes. Highlighted rows mark common stock sizes. Real stock varies slightly with tolerances and corner radii.
| Profile & Size | Cross-Section | Lb per Foot | 12 ft Length | Kg per Meter |
|---|---|---|---|---|
| Flat bar, 1 × 1/8 in | 0.125 sq in | 0.146 lb/ft | 1.76 lb | 0.218 kg/m |
| Round tube, 1 in OD × 0.065 in wall | 0.191 sq in | 0.224 lb/ft | 2.68 lb | 0.333 kg/m |
| Round bar, 1/2 in dia | 0.196 sq in | 0.230 lb/ft | 2.76 lb | 0.342 kg/m |
| Hex bar, 1/2 in across flats | 0.217 sq in | 0.253 lb/ft | 3.04 lb | 0.377 kg/m |
| Square bar, 1/2 in | 0.250 sq in | 0.293 lb/ft | 3.51 lb | 0.436 kg/m |
| Flat bar, 2 × 1/4 in | 0.500 sq in | 0.585 lb/ft | 7.03 lb | 0.871 kg/m |
| Round tube, 1.5 in OD × 0.125 in wall | 0.540 sq in | 0.632 lb/ft | 7.59 lb | 0.941 kg/m |
| Round tube, 2 in OD × 0.125 in wall | 0.736 sq in | 0.862 lb/ft | 10.35 lb | 1.283 kg/m |
| Round bar, 1 in dia | 0.785 sq in | 0.920 lb/ft | 11.03 lb | 1.368 kg/m |
| Hex bar, 1 in across flats | 0.866 sq in | 1.014 lb/ft | 12.17 lb | 1.509 kg/m |
| Square bar, 1 in | 1.000 sq in | 1.171 lb/ft | 14.05 lb | 1.742 kg/m |
| Sheet strip, 12 × 1/8 in | 1.500 sq in | 1.756 lb/ft | 21.08 lb | 2.614 kg/m |
| Flat bar, 4 × 1/2 in | 2.000 sq in | 2.342 lb/ft | 28.10 lb | 3.485 kg/m |
| Round bar, 2 in dia | 3.142 sq in | 3.678 lb/ft | 44.14 lb | 5.474 kg/m |
For another alloy, multiply by its density ÷ 168.6 — for example, × 1.04 for 7075 or × 0.99 for 5052. Hex bar is measured across the flats.
Aluminum Alloy Densities and Sheet Weights by Thickness
The table on the left lists the calculator’s alloy densities in pounds per cubic foot, pounds per cubic inch, and grams per cubic centimeter. The table on the right gives the weight of aluminum sheet and plate per square foot and for a full 4 × 8 ft sheet at common thicknesses, using 6061.
| Alloy | lb/ft³ · lb/in³ | g/cm³ |
|---|---|---|
| 5083 | 166.1 · 0.0961 | 2.66 |
| 5052 | 167.3 · 0.0968 | 2.68 |
| 6063 | 167.9 · 0.0972 | 2.69 |
| 6061 | 168.6 · 0.0976 | 2.70 |
| Pure Al | 168.6 · 0.0976 | 2.70 |
| 1100 | 169.2 · 0.0979 | 2.71 |
| 3003 | 170.4 · 0.0986 | 2.73 |
| 2024 | 173.5 · 0.1004 | 2.78 |
| 7075 | 175.4 · 0.1015 | 2.81 |
| Thickness | Per sq ft | 4 × 8 sheet |
|---|---|---|
| 0.032 in | 0.45 lb | 14.4 lb |
| 0.040 in | 0.56 lb | 18.0 lb |
| 0.063 in | 0.89 lb | 28.3 lb |
| 0.080 in | 1.12 lb | 36.0 lb |
| 0.090 in | 1.26 lb | 40.5 lb |
| 1/8 in (0.125) | 1.76 lb | 56.2 lb |
| 3/16 in (0.190) | 2.67 lb | 85.4 lb |
| 1/4 in (0.250) | 3.51 lb | 112.4 lb |
| 3/8 in (0.375) | 5.27 lb | 168.6 lb |
| 1/2 in (0.500) | 7.03 lb | 224.8 lb |
Aluminum Weight — Key Numbers
The Aluminum Weight Calculator Is Built For You If…
Whether you’re quoting a fabrication job, building a trailer or boat, ordering bar stock, or estimating a shipping weight, this calculator turns aluminum sizes into accurate weights in seconds.
Machinists, Welders & Fabricators
Quotes, cut lists & material ordersAluminum stock is bought by the pound, and material is a big part of every quote. A fabricator can price a run of 2 × 1/4 in flat bar from its 0.585 lb/ft weight, or check whether a 1/4 in 4 × 8 plate (about 112 lb) needs two people to handle. The pieces table scales a single part to a production run.
- Use weight per foot to price cut lengths from full bars
- Enter the actual alloy for 2024 and 7075 aerospace work
- Price per pound for stock; per ton for scrap
- Attach the PDF to quotes and purchase orders
DIY Builders & Makers
Trailers, boats, racks & projectsWeight is often the reason to choose aluminum in the first place. When building a trailer, boat accessory, roof rack, or shop fixture, the calculator shows what each tube, bar, and sheet adds — and how much you save compared with steel, which is roughly 2.9 times heavier for the same size.
- Add up each part of a frame to estimate total build weight
- Compare tube wall thicknesses to balance strength and weight
- Use 5052 or 5083 for marine sheet, 6061 for most structural parts
- Enter sizes in mm for metric stock
Contractors, Architects & Shippers
Railings, facades, framing & freightAluminum railings, window and storefront framing, facade panels, and canopies all need weight estimates for design loads, handling, and freight. Architectural extrusions are commonly 6063, and panels are often 3003 or 5052. Shippers need total weight in pounds and kilograms for quotes and customs paperwork.
- Use 6063 for architectural extrusions and railings
- Report kilograms for international freight
- Add packaging and crating separately from metal weight
- Confirm complex extrusions with the manufacturer’s lb/ft
7 Tips for Accurate Aluminum Weight Estimates
The math is exact, but the profile you choose, the units you enter, and how you read a size designation make the difference. These tips help you get a number you can quote and ship with.
Measure Hex Bar Across the Flats
Hex bar is sized by the distance between two flat faces, not corner to corner. Enter that across-flats size; the calculator uses 0.866 × AF² for the area. Entering the corner-to-corner size would overstate the weight by about a third.
Use the Tube Profile for Anything Hollow
Round tube and pipe are mostly air. Enter the outer diameter and wall thickness in the Round tube profile — a solid round bar of the same diameter can weigh several times more. For square or rectangular tube, use the manufacturer’s lb/ft or calculate the wall area separately.
Watch Your Units — Especially Thickness
Thickness and wall are usually in inches (0.125, 0.063) while length is usually in feet. Each field has its own unit selector, including mm for metric stock. A thickness entered in feet instead of inches is a twelvefold error, so double-check before quoting.
Know That Pipe Sizes Are Nominal
Aluminum pipe is often labeled by a nominal size and schedule rather than its actual outer diameter and wall. Look up the actual OD and wall thickness for the size and schedule, then enter those numbers for an accurate weight.
Pick the Right Alloy — but Don’t Sweat It
Alloy choice changes weight by only about 5–6% from lightest (5083) to heaviest (7075). If you don’t know the alloy, 6061 is a sensible default. When billing or aerospace weight budgets depend on it, select the exact alloy or enter a mill-spec density.
Allow for Tolerances and Corner Radii
Real bar and tube have rounded corners, and mill tolerances allow slight over- or under-size. Nominal calculations are usually close, but for tight weight budgets or large orders, compare against the supplier’s published weight per foot.
Include Cutting Waste When Ordering
Stock usually comes in full lengths such as 12 ft bars or 4 × 8 ft sheets, and saw kerf and offcuts add up. Calculate the weight of the full stock you’ll buy, not just the finished parts, when estimating material cost and shipping weight.
Aluminum Weight Calculator — Frequently Asked Questions
Everything you need to know about calculating aluminum weight for sheet, plate, bar, and tube, alloy densities, and how aluminum compares with steel.
Multiply the cross-section area by the length and by the alloy’s density. With inches, weight (lb) = cross-section (sq in) × length (in) × about 0.0976 lb per cubic inch for 6061.
For example, a sheet strip 12 in wide, 1/8 in thick, and 8 ft long has a 1.5 sq in cross-section and a 96 in length, so it is 144 cubic inches × 0.0976 ≈ 14.05 lb, or about 1.76 lb per foot.
It depends on the thickness. In 6061, a 4 ft × 8 ft sheet weighs about 18 lb at 0.040 in, 28.3 lb at 0.063 in, 36 lb at 0.080 in, 56.2 lb at 1/8 in (0.125 in), 112.4 lb at 1/4 in, and 224.8 lb at 1/2 in.
A quick rule is about 14 lb per square foot for every inch of thickness.
Aluminum is about 2.70 grams per cubic centimeter, which is about 168.6 pounds per cubic foot or 0.0976 pounds per cubic inch (6061 alloy).
Common alloys range from about 2.66 g/cm³ for 5083 to about 2.81 g/cm³ for 7075.
Slightly. The calculator’s alloys range from 5083 at about 166.1 lb per cubic foot to 7075 at about 175.4 lb per cubic foot, a difference of roughly 5.6 percent.
Alloys with more copper or zinc, such as 2024 and 7075, are a little heavier; magnesium-bearing alloys such as 5052 and 5083 are a little lighter. For most estimates 6061 is a good default.
Use the wall’s cross-section: area = π ÷ 4 × (outer diameter² − inner diameter²), where the inner diameter is the outer diameter minus twice the wall thickness. Multiply by length and density.
A 1.5 in OD tube with a 0.125 in wall has a 0.54 sq in cross-section and weighs about 0.63 lb per foot in 6061, or about 7.6 lb for a 12 ft length.
Hex bar is sized by the distance across the flats. Its cross-section area = √3 ÷ 2 × (across flats)², or about 0.866 × AF².
A 1 in hex bar has a 0.866 sq in cross-section and weighs about 1.01 lb per foot in 6061.
Aluminum weighs about one third as much as steel for the same size. 6061 aluminum is about 168.6 lb per cubic foot, while carbon steel is about 490 lb per cubic foot, so the same piece in steel is roughly 2.9 times heavier.
A 1/4 in 4 × 8 ft aluminum plate weighs about 112 lb; the same plate in steel weighs about 327 lb.
The geometry is exact: each dimension is converted to feet (1 in = 1/12 ft, 1 mm = 1/304.8 ft), the cross-section is calculated for the chosen profile, and weight = cross-section × length × density, with 1 lb = 0.45359237 kg exactly.
Real stock differs slightly from nominal size because of mill tolerances, corner radii on bar and tube, and the exact alloy and temper, so confirm against a mill spec or supplier weight for critical loads.
Accuracy note: The HomeExpertly Aluminum Weight Calculator converts each dimension to feet using 1 in = 1/12 ft and 1 mm = 1/304.8 ft, calculates the cross-section for the chosen profile (sheet and flat bar W × T; round bar π ÷ 4 × d²; round tube π ÷ 4 × (OD² − ID²); square bar s²; hex bar √3 ÷ 2 × AF²), and applies weight = cross-section × length × density × pieces, with 1 lb = 0.45359237 kg (exact) and 1 short ton = 2,000 lb. Alloy densities (6061 168.6, 6063 167.9, 1100 169.2, 3003 170.4, 5052 167.3, 5083 166.1, 2024 173.5, and 7075 175.4 lb/ft³) are typical published values. Calculations use nominal dimensions; mill tolerances, corner radii, coatings, and finishes change real weights slightly, and complex extrusions should be checked against the manufacturer’s weight per foot. Cost estimates depend entirely on the price you enter. Results are for informational and planning purposes only. Confirm weights against a mill spec or supplier data before quoting, shipping, lifting, or designing for critical loads. HomeExpertly is not responsible for any consequences arising from the use of these estimates.