Description

GA’s Aluminium Flat Bar is a rectangular-section extrusion — the most elemental and widely used form in the aluminium profiles range. Manufactured from architectural-grade 6063 aluminium alloy to BS EN 755, 515, and 573 standards, this profile offers a clean, flat bearing surface on all four faces with no complex geometry to constrain how it is cut, drilled, bent, or welded.

Stocked in nine widths from 9.5mm to 101.6mm, all at a uniform 3.2mm thickness. This single, consistent wall thickness means there is no risk of specifying the wrong wall when ordering — simply select the width you need. Available in mill (untreated) or natural anodised surface finish. Stock lengths are 4 metres.

Should you require a powder coated finish or cut pieces, we can do this for you, please contact our Sales Team. While browsing our product listings, please click the illustrated images for dimensional details.

Notes. Jig marks, up to 50mm in from each end (often less than this), can be apparent on anodised items. These marks can be cut away before fixing.

Shade variations can occur with anodised surfaces due to the reactive nature of this finishing process.

Health and Safety

(Health and Safety doc. (1).pdf, 240 Kb) [View Document]

Install

(Profiles and Extrusions Install (5).pdf, 238 Kb) [View Document]

Maint.

(Maintenance of Aluminium Surfaces (1).pdf, 232 Kb) [View Document]

Tech Data

(Tech info extrusions (4).pdf, 397 Kb) [View Document]

Test Data

(Test – Extrusion Resistance to Surface Marking.pdf, 227 Kb) [View Document]

Aluminium Flat Bar

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Product Code: Categories Aluminium Profiles & Extrusions, Flat Bar Product Type: Aluminium Flat Bar

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Specifications

Profile Type: Rectangular Flat Bar

Widths Available: 9.5mm, 12.7mm, 15.8mm, 19.0mm, 25.4mm, 31.7mm, 38.1mm, 50.8mm, 76.2mm, 101.6mm

Thickness: 3.2mm (uniform across all sizes)

Material: Grade 6063 Aluminium Alloy

Standards: BS EN 755, BS EN 515, BS EN 573

Anodising Standard: BS EN ISO 7599

Powder Coating Standard: BS 6496 (1984) — available to order, please contact Sales

Length: 4 metres (4000mm) standard stock length

Available Finishes: Mill (Untreated) or Natural Anodised

Surface Marking Test: Independent testing (Ceram / Lucideon) on GA 0178 (101.6 x 3.2mm flat bar): anodised finish achieved up to 4× greater abrasion resistance than mill finish

Finish Notes: Anodised product codes carry an ‘s’ suffix (e.g. GA 0178s). Jig marks within 50mm of each end are standard and can be trimmed during final fitting. Shade variations may occur between batches.

Key Benefits

No-Geometry Versatility: Unlike angle, tee, or channel sections, a flat bar places no geometric constraints on how it is used. It can be fixed flat, stood on edge, bolted, riveted, welded, or bent to a radius without any profile geometry getting in the way. This makes it the go-to profile whenever a fabrication task calls for a bespoke solution.

Consistent Single Thickness Across the Range: Every flat bar in GA’s stock range shares the same 3.2mm wall thickness, with width as the only variable. This simplifies specification and minimises the risk of ordering errors — particularly useful when multiple widths are required within the same project or fabrication run.

Test-Proven Anodised Surface Hardness: The GA 0178 — our 101.6mm flat bar — was the sample used in independent surface marking tests carried out by Ceram Building Technology (now Lucideon). Results showed that our natural anodised surface withstands up to four times as many abrasion passes as mill finish before visible damage occurs. This is independently verified data, not a general claim.

Outstanding Corrosion Resistance: The 6063 alloy grade provides excellent resistance to atmospheric corrosion and moisture without any surface treatment. Flat bars used as external trims, outdoor fixtures, or structural components perform reliably over the long term with minimal maintenance.

Excellent for Welding: 6063 is specifically rated as excellent for welding in GA’s technical data, and the flat bar’s simple rectangular cross-section makes it straightforward to prepare and join. Whether used as a backing strip, a welded structural strap, or a component within a larger fabrication, clean, strong welds are readily achievable.

Applications

Cover Strips, Trims & Jointing Plates: Aluminium flat bar is the standard choice for covering exposed joints, sealing panel edges, and creating neat face-fixed trims across wall cladding, internal linings, and composite panel installations. The clean rectangular face sits flush against any substrate and can be anodised to complement surrounding metalwork for a consistent, professional finish.

Structural Straps, Ties & Fixing Plates: Used extensively in light structural fabrication to create connecting straps between members, load-spreading plates beneath fixings, and lateral ties within frame assemblies. The flat bar’s uniform section makes it straightforward to drill at any position along its length, and its 3.2mm wall provides some shear resistance for typical fixing loads.

Electrical & Electronics Applications: Aluminium flat bar is widely used as a conductor bar in low-voltage electrical distribution, and as a heat-spreading element in LED lighting assemblies and electronic enclosures. The high thermal conductivity of 6063 alloy draws heat away from components efficiently, and the bar’s rectangular profile is easy to machine for mounting holes, slots, or connector positions.

General Fabrication, Spacers & Bespoke Components: The flat bar’s unrestricted geometry makes it the default starting point for one-off and short-run fabrication work. Used as spacers and packing shims in mechanical assemblies, as shelf support brackets, as framing reveals behind other profiles, and as base components for welded structures where a simple, predictable rectangular section is needed at the outset.