Mistakes to Avoid While Using Standard Aluminium Extrusions

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Mistakes to Avoid While Using Standard Aluminium
Extrusions
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Introduction

• Aluminium extrusions are a versatile building
  material used widely in various industries.
  However, there are some common mistakes made
  during their application that can compromise the
  structural integrity and longevity of projects.
  This article discusses eight such mistakes to
  avoid when using standard aluminium extrusions.
  Following these tips will help you get the best
  performance from extrusions and prevent expensive
  repairs or replacements down the line.

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Not Choosing the Right Profile

• Aluminium extrusions come in different shapes and
  sizes known as profiles. The most common profiles
  include square, rectangular, round and T-shape.
  Choosing the wrong profile can compromise the
  structural integrity of your project. Make sure
  to carefully measure the required dimensions and
  choose a profile that fits your needs. For
  example, a square profile works well for framing
  while a T-shape profile provides strength and
  rigidity.

4
Not Considering Weight Limits

• While aluminium is lightweight, extrusions still
  have weight limits depending on their intended
  use. Exceeding the recommended weight limits can
  cause the extrusion to bend or break over time
  under stress. Factors like wind loads or
  additional attachments need to be accounted for.
  Consult extrusion manufacturers for weight
  bearing capacities of different profiles. This
  prevents unexpected failures.

5
Not Applying Protective Coatings

• Aluminium is corrosion resistant but not
  corrosion proof. Without protective coatings,
  extrusions can develop surface oxidation when
  exposed to moisture, chemicals or pollution over
  time. This affects the aesthetic appeal. Apply
  powder coated, anodized or painted finishes
  suited for outdoor or harsh indoor environments.
  Coatings also improve scratch and abrasion
  resistance.

6
Not Allowing for Thermal Expansion/Contraction

• Aluminium expands and contracts with changes in
  temperature. Without allowance for this movement,
  joints can become loose or connections may break.
  Ensure sufficient gaps, overlays or sliding
  joints when assembling extrusion frames or
  structures. Also avoid rigidly fixing extrusions
  that need free movement due to temperature
  fluctuations.

7
Not Using Compatible Connectors and Fasteners

• Many connector and fastener options are available
  but not all are suitable for aluminium. Using
  incompatible materials can lead to corrosion,
  galvanic reactions or stripping of threads.
  Stainless steel is a common matching material.
  Also ensure connectors are tightened to the
  recommended torque to prevent loosening over time.

8
Not Accounting for Drilling and Cutting Tolerances

• Aluminium is relatively soft and workable but
  drills and saw blades still have a kerf or
  cutting width. Not compensating for these
  tolerances during marking out can result in holes
  or cuts that are slightly larger than intended.
  This affects the fit of connectors, panels or
  other attachments. Allow for tool sizes to get
  accurate cuts and holes.

9
Not Bracing and Reinforcing Where Needed

• While aluminium extrusions are strong for their
  weight, they need reinforcement at points of
  heavy loading or where two members meet at an
  angle. Brackets, gussets or splice plates add
  rigidity without adding much weight. Proper
  bracing prevents bending, buckling or breakage of
  extrusions under stress. Consult engineering
  drawings for guidance on reinforcing structural
  joints.

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Not Considering Maintenance Requirements

• Even coated aluminium needs periodic cleaning,
  touch-ups and inspections. Neglecting maintenance
  can lead to corrosion developing underneath
  surface coatings over time. Have a plan to access
  all areas for cleaning and repairs. Also inspect
  for damage after extreme weather events. With
  proper care and maintenance, aluminium extrusions
  can last for many years.

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Conclusion

• Following these tips helps get the most out of
  standard aluminium extrusions for various
  construction and fabrication needs. Choosing the
  right Aluminium Section solar panel, applying
  protective finishes, allowing for movement and
  using compatible hardware are some key things to
  keep in mind. With proper planning and
  installation, aluminium extrusions can be used to
  build durable and long-lasting structures.